Home

TUBE-ICE® MACHINE - Whaley Food Service

1. BT FPS 24 2 O 8 1 07 FIGURE 6 2 Control Panel 10 Service Manual ELECTRICAL CONTROLS Item No Vogt Part No Description AX 12A7518E33UL Aux Indicator INO INC BT 12A2117G09 Bin Thermostat Optional CB 12A7515E21 Control Circuit Breaker 3 Amp 2 Pole 12A7515E33 Control Circuit Breaker 4 Amp 2 Pole 400V 50Hz only 12A7516E30 Compressor Motor Contactor 72 Amp 3 Pole CC 12A7518E30 Aux Contact 10 Amp 1 N O 1 N C Side Mount 400 460V 12A7518E31 Aux Contact 10 Amp 2 N O Side Mount 12A7518E32 Aux Contact 5 Amp 2 N O Top Mount 12 7516 48 Compressor Motor Contactor 140 Amp 3 Pole dx LLI2ATSISEA3 Aux Outside Contact 2 Amp 2 N O Side Mount 12A7518E44 Aux Inside Contact 2 Amp 2 N O Side Mount CR 12A7517E27 Control Relay 10 Amp 2 N O 2 N C 208 240V Coil 12A7516E23 Contactor 9Amp 3 Pole with 1 N O Aux 208 240V Coil CU 12A7530E52UL Cutter Manual Motor Starter 0 63 1 0A 460V 60hz 12A7530E53UL Cutter Manual
2. 3 6 Rotation Check o RUD HE RI RUM HEN URDU UR ERU ANI INE 3 6 Air Cooled Condenser Installation Instruetons 3 7 Pounds of R 22 to Add Vs Liquid Line Length TABLE 3 3 eene rentrer 3 8 Air Cooled Condenser Data TABLE E 3 9 Condenser Dimensions AUREA cts Condenser Field Piping Cold Weather Valve Kit FIGURE 3 5 Equivalent Feet Due To Friction TABLE 325 0 al Minimum Traps For Discharge Lines FIGURE Ap Wiring For DD 591 and DD 661 Condensers 3 phase motors FIGURE 3 7 sse 3 12 Tee Bin Thermostat Sensor eL ee E 3 13 Typical Bin Sensor Mounting 9 3 13 Programming Electronic Bin Thermostat eene netten eet 3 14 Installation Review A Checklist as o a 3 15 bel e 10 Service Manual TABLE OF CONTENTS Page No 4 HOW YOUR TUBE ICE MACHINE WORKS Pnn ciple oft Oper atioliz Ete e does 4 1 Freeze Period A ened E say ss 12 4 2 Harvest Le 4 2 Piping Nomenclature eie terr te HEC RPM ener tee 4 2 Water Cooled Piping Schematic FIGURE ATI 4 3 Air Cooled Piping Schematic FIGURE A 4 4 5 START UP AND OPERATION Refriger tiom System REVIEW 5 1 R trigerant Charge ERR E ERR RE In ge agmen 5 1 Start up Procedure is io eroe eter eR qan He e 5 2 Control Panel Switch Layout FI
3. 5 2 00 O To e U Cep e E c d y 1 ia Q 7 0 l E E C m 2 S 2 N 5 SS lt H oe Y D C5 2 Es A i gt A IW 2 ES O m o Ge om Ce gt 2 tal z 92 a be my E 22 4 5 3 ox m 2 2 3 KE LI KC l NN D er M SS gt 3 Y tI 3 C Z Li all NJ lt SS m 00 2 hj lt e ONILV INDIO n FIGURE 4 2 Air Cooled Piping Schematic 8 1 2007 8 1 07 10 Service Manual 5 1 START UP AND OPERATION Start Up and Operation Refrigeration System Review The refrigeration system uses R 22 or R 404a refrigerant a compressor a refrigerant float switch expansion valve a flooded evaporator freezer and warm gas defrost Following the schematic you see that during the freeze period of the machine s cycle the condenser discharge gas leaves the compressor and goes to the condenser where it is condensed into liquid by the removal of heat by either air or water passing through the condenser A reservoir of liquid is accumulated in the receiver and flows as required passing through the thawing chamber a lower separate section of the freezer then the filter drier The liquid feed solenoid valves A1 and A2
4. 9 10 Control Panel Parts 6 1 6 3 Control Relay CR 6 2 6 3 6 4 Cooling Tower 3 2 12 1 INDEX Crankcase Heater 7 6 9 10 Crushed Ice Production 9 21 Cutter amp Bearing Removal Installation 9 18 Cutter Drive Parts 9 20 Cutter Gear Reducer 7 7 9 16 9 17 Cutter 9 17 Cutter Assembly 9 19 Cutter Bearing 9 18 Cutter Bearing Support 9 18 Cutter Disc Assembly 9 19 Cutter Drive Parts 9 20 Cutter Gear Reducer 9 16 9 17 Cutter Motor Cutter Assembly 9 19 Cutter Parts crushed Ice 9 21 Cutter Parts cylinder ice 9 19 D D Valve Thawing Gas 4 1
5. 6 3 6 4 9 11 Thermostat Bin Installation 3 13 Thermostat Setup 3 14 Timer Thawing 6 3 6 4 9 11 Trap AC Piping 3 11 Troubleshooting 8 1 Troubleshooting Power Monitor 10 4 U Unloader Loaded Operation Freeze Period 9 15 V Vitals Operation 11 5 W Warranty Basic inside back cover Water Conditioning 3 1 10 Service Manual Water Cooled Condenser 3 2 3 4 7 4 Water Cooled Condenser Cleaning 7 5 Water cooled Machine Installation 3 4 Water Cooled Piping Schematic 4 3 Water Cooled Units 9 5 Water Distributors 7 3 Water Pump 9 16 Water Quality 3 1 Water Regulating Valve 9 5 Water Supply
6. Meee eee 7 10 8 TROUBLESHOOTING List OE Symptomisu q erger See niter 8 1 Worn E EES EES 8 1 8 2 Freeze Up Due To Extended Freezing Period u a u eese 8 2 Freeze Up Due Ice Failing To Discharge nennen ener rennen ert tne 8 3 Ice Quality A Eo e RI PEE ERR do E AMO eet 8 3 Capacity series ernie eeu e Dei i 8 4 Low Compressor Oil evi A A A A 8 4 High Head Pressure Water Cooled aaa 8 5 High Head Pressure Air Cooled suan A CR P RR ae eoe pne ERR E edP aa 8 5 9 SERVICE OPERATIONS Adjustable Blowdown For Clearer lee 9 1 Water pump Blowdown Assembly FIGURE OI 9 1 Automatic Blowdown Harvest Cycle 9 1 Float Valve Make Up Wat eee i t eet este diet eee eeh 9 1 etii oie na 9 2 Float FIGURE 0 2 Net e rr EE S re E dee Y RSS EARN 9 2 Hand Expansion Valy z u aia Freezer Pressure Switch Freezer Pressure Switch Allen Bradley 9 9 3 Capillaty EE 9 4 High Low Press re SWIHCh EE RORIS ICE a 9 4 High Low Pressure Switch FIGURE O A 9 4 Head Pressure o u ER PR USD RFT SIR eR NE e ipee rd EE DRM tente i tet 9 5 Water Cole BEE 9 5 Air Coole d US Ai 9 5 Water Regulating Valve FIGURE 9 54 9 5 Condenser F n Switch
7. ECH RETURN QUID LN x 2 5 K D E eL oof oo s o o m 4 3 HOW YOUR TUBE ICE MACHINE WORKS GE HAR SC OIL RETURN l QUID LINE d LIQ COMPR 3 FIGURE 4 1 Water Cooled Piping Schematic JMP 6 4 4 10 Service Manual HOW YOUR TUBE ICE MACHINE WORKS i0NVH2SlI SS Co c d lt Bech Lu e I Eo D 44
8. 2 FLA for 200 volt models is approximately 2 times that of 380 volt models Total FLA does not include cooling tower 3 Makeup water is maximum value and includes 10 gallons per cycle blowdown 4 Condenser flow rate is for 85 F entering water temperature and 100 F condensing 5 Tower sized for 80 F wet bulb temperature 6 Recommended air cooled condenser is based on 15 F TD Vogt reserves the right to change designs and specifications without notice Table 11 2 8 1 07 11 4 10TA Service Manual TABLES amp CHARTS P18FXT Capacity Ratings Rated Capacity Ibs day r Cylinder Cylinder Deg F 1 11 4 112 1 114 1127 1 114 1127 1 1144 112 40 21700 19100 17600 22568 19864 18304 21700 19100 17600 22568 19864 18304 42 21620 19060 17560 22485 19822 18262 21620 19060 17560 22485 19822 18262 43 21580 19040 17540 22443 19802 18242 21580 19040 17540 22443 19802 18242 21500 19000 17500 22360 19760 18200 21500 19000 17500 22360 19760 18200 21320 18880 17380 22173 19635 18075 21320 18880 17380 22173 19635 18075 21260 18840 17340 22110 19594 18034 21260 18840 17340 22110 19594 18034 17451 17410 17368 17326 17285 17243 17202 17160 71 17004 75600 18990 18600 7a 16600 15300 19888 17472 18912 16640 16800 15206 18580 178
9. Low refrigerant charge Insufficient blowdown during harvest 8 3 TROUBLESHOOTING Freeze up due to ice failing to discharge POSSIBLE CAUSE POSSIBLE REMEDY The head pressure should be maintained at approximately 210 PSIG which relates to 105F 37 8C This is done by a water regulating valve water cooled units FIGURE 9 5 Section 9 or a Fan cycling switch air cooled units FIGURE 9 5 Section 9 If non condensables are present with the refrigerant the saturated temperature will not relate to the pressure reading at the receiver The refrigerant level in the receiver should be near the operating mark at the end of a freezing cycle to provide enough volume for harvesting 1 approx 11 lbs of R22 Check the thaw timer T which should be adjusted to allow all the ice to clear the cutter and ice discharge opening with at least 30 seconds to spare Check cutter reducer and drive gear for proper operation and alignment Check for broken cutter disc or drive pin and replace as necessary Ice mushy due to concentration of solids in the water tank Perform Cleaning Procedure and check automatic and adjustable blowdown If the machine discharges ice into a chute it should slope at an angle of 30 degrees for cylinder ice and 45 degrees for crushed ice Check bin stat or level control to make sure it will stop the machine before ice backs up into the cutter Check freezer pressure switch adjustment see FIGURE 9
10. TABLE 7 2 Average Hole Size In Tube Ice Water Tank The production of opaque ice can indicate that the water in the water tank contains a concentrated amount of solids or salts Remove cover plate Open drain valve 28 Clean tank thoroughly by flushing out with a hose and scrubbing with a stiff brush It may be necessary to completely remove the water tank in order clean all surfaces After cleaning close drain reinstall tank if necessary and fill the water tank with fresh water When restarting the machine be sure that the water pump is circulating water It is possible that air may have collected in the pump impeller housing and the pump may have to be stopped and started several times to expel the air Freezer Cover A clear polycarbonate freezer cover is provided for visual inspection of the water box and water distributors located at the top of the freezer The cover should be removed and cleaned if it becomes coated with deposits Generally if the freezer cover is coated with solids this is a prime indicator that the other areas 1 e water tank and distributors also require cleaning 7 4 IOTA Service Manual MAINTENANCE Water Cooled Condensers Checking Operation How often condensers need cleaning depends on so many variables that it is impossible to recommend a schedule Some will seldom need cleaning others perhaps need cleaning once a year In rare cases cleaning is required several times a year Proper operation of coo
11. 9 12 Refrigeration System Review 5 1 Rotation Check 3 6 S Safety Notice 1 2 Safety Symbols and What They 1 3 Safety Valves 2 1 Sanitizing Procedure 7 2 Shipping Papers 2 1 Solenoid Valve 9 14 Space Diagram Air Cooled Machine 3 3 Space Diagram Water Cooled Machine 3 4 Special PrecautionS 1 2 Start Push Button PB1 5 2 5 8 6 3 Start Up 5 2 Start Up Checklist 3 15 Storage prior to installation and start up 2 2 Suction Cut Off Unloader 9 15 Symptoms Troubleshooting 8 1 T Telephone Number Vogt 1 1 Temperature Pressure Chart 11 7 Thawing Chamber 4 1 Thawing Timer T
12. IMPORTANT Installation Review A Checklist Make a visual check to be sure these steps have been taken BEFORE continuing CHECK PRIOR TO OPENING VALVES check all joints for leaks which may have developed during shipment NOTE the machine was shipped with a positive pressure of 20 25 PSIG verify on the freezer pressure gage CHECK _ The system is properly evacuated to 500 microns CHECK refrigerant piping water supply and drain connections for conformity to requirements stipulated in this manual and properly connected to inlets and outlets CHECK Electrical supply for proper size of fuses and for compliance to local and national codes See the machine nameplate for minimum circuit ampacity and maximum fuse size CHECK field installed equipment augers conveyors cooling towers bin level controls etc for proper installation CHECK The applicable portion of the warranty registration start up report for proper completion CHECK Cutter gear reducer oil level oil should run out of side pipe plug when removed CHECK The water distributors at top of freezer to make sure they are all in position CAUTION The compressor crankcase heater should be energized for a minimum of Two 2 hours before attempting to start the compressor CAUTION 6 15 05 10 Service Manual 8 1 2007 4 1 HOW YOUR TUBE ICE MACHINE WORKS 4 How Your Machine Works Principle Of Opera
13. Pump Discharge 1 1 2 FPT Pump Suction 2 FPT Seal Kit Part 12 4080 12 Pump Part 12A4020G01 60hz 12A4020G08 5017 FIGURE 9 12 Circulating Water Pump Cutter Gear Reducer Part No 12 4030 12 The oil level for the gear reducer should be checked if there is evidence of a leak It should be level with the plugged opening in the side of the gear housing Use Mobile 600W cylinder oil or equal Change oil once a year The motor bearings are prelubricated and require no further lubrication For additional information refer to manufacturer s instructions Gear Reducer 10 1 Part 12A4030R12 Replacement food grade oil Part 19T3020C01 Texaco Cygnus 220 Oil Capacity 8 ounces Drain Plug Oil Level Plug FIGURE 9 13 Gear Reducer Component Removal and Replacement Operations 8 21 06 8 21 06 10 Service Manual 9 17 SERVICE OPERATIONS Cutter Motor The cutter motor s bearings are prelubricated and sealed and require no further lubrication If the motor needs replacing proceed as follows SA gt 10 Turn power off and lockout disconnect Check terminals with voltmeter to confirm power is off Remove motor terminal cover and disconnect wires Mark wires for ease of replacement Remove four cap screws around the motor flange and separate the motor from the reducer Watch for shaft key that must be reinstalled later Check the motor electrically to confirm it is defective Apply
14. Vogt 10TA TUBE ICE MACHINE Includes model P18FXT Manual Part Number 12 4171 08 Revision 2 Service Manual 500 NOTICE This manual is the property of the owner of this particular Tube Ice machine Model 0 It is to be left on the premises with this machine at all times After start up it should be stored in a safe place where it can be readily available when needed for future reference in maintaining troubleshooting or servicing Failure to comply with this notice will result in unnecessary inconvenience and possible additional expenses This manual is intended as an informational tool for the installation operation maintenance troubleshooting servicing of this equipment If an existing situation calls for additional information not found herein we suggest that you contact your distributor first If further assistance or information is needed please feel free to contact the factory at 502 635 3000 or FAX at 502 635 3024 IMPORTANT The Warranty Registration Start Up Report found in the front of this manual is to be completed and returned to the factory promptly after the official start up Please return to TUBE ICE LLC 1000 W Ormsby Ave Suite 19 Louisville KY 40210 Tube Ice L L C Vogt Order Number 1000 W Ormsby Louisville KY 40210 502 635 3235 FAX 502 635 3024 THIS FORM MUST BE SENT TO VOGT TO ACTIVATE WARRANTY Warranty Registration St
15. e N N 0 e ZA z min hrs 10h Thawing Timer Part 12A7503E22 The thawing timer governs the ice thawing period It is located inside the control panel FIGURE 6 2 It is started by action of the freezer pressure switch FPS which energizes the relay Set the thawing period for at least 30 seconds longer than the time required to harvest the entire discharge of ice If it should be necessary to change the setting of the timer turn the adjustment screw clockwise to increase the time or counter clockwise to decrease the time Verify time after each adjustment 6 5 4 3 VOUS FIGURE 9 9B Thawing Timer Wiring Pumpdown The function of the pumpdown is to transfer all the liquid refrigerant from the freezer evaporator into the receiver Pumpdown should only be performed when the freezer is clear of ice Its main purposes are 1 To check the total refrigerant charge 2 To perform service or repair work on machine 8 21 06 9 1 8 21 06 2 10TA Service Manual SERVICE OPERATIONS 3 To winterize the machine 4 To prepare the machine for disconnecting and moving 5 Before cleaning To perform a pumpdown follow this procedure l 3 Push manual harvest button to clear the freezer of all ice and stop operation Close the liquid stop valve king valve 58 at the receiver Open the water tank drain valve partially to allow a continuous flow of wa
16. 9 14 Drive gear 9 20 E Electrical Connection 3 5 Electrical Schematic All Voltages 50 60 Hz 6 5 Electrical Controls 6 3 Enclosure Energy 1 1 Equivalent Feet Due To Friction 3 11 F Fan Contactor FC 6 2 6 8 6 4 Filter Drier JJ JJJJs lt Jr 4 1 Float Switch J JJ gJ JJ 9 2 Float Valve Make Up Water 9 1 Freeze Period 4 2 Freeze Up Due To Extended Freezing 8 2 Freeze Up Due To Ice Failing To Discharge 8 3 Freezer 4 1 Freezer Pressure Switch 9 3 G Gear Reducer 9 16 H Hand Expansion Valve 9 3 Harvest Period 4 2 Head Pressure 9 5 Heat Exchanger 4 1 Heater Crankcase 9 10 High Head Pressure Air
17. 9 1818 275000 4 7 275000 97 34 u 20 uu os 95 uo f m9 215000 275000 Table 11 4 Condenser Water Usage Cylinder Ice Crushed Ice Make Up Water Tube Size Temp F 11 2 242 216 20 284 253 80 f 214 193 186 249 225 01 19 174 168 225 202 Includes 10 gallons per cycle blowdown Table 11 5 Make Up Water Usage gpm Suction Pressure Discharge Pressure Harvest Times Ice per Freeze Time psig psig secs cycle minutes End of Freeze Average during Freeze First All Ice Total Average Water Temperature deg F 7 Out Harvest A C Y L 20 150 Ibs 117 104 93 89 86 235 198 178 160 15 6 152 105 175 117 104 93 789 86 175 105 175 Table 11 6 Normal Operating Vitals 175 EA A 8 1 07 11 6 TABLES amp CHARTS QTY 8 1 07 PART NUMBER 12A2117E04 12A7503E22 12A7517E27 12A7516E23 See Page 6 3 See Page 6 3 12A2900M0508 12A4200H0402 1282020 01 12A2600G15 12A2600G05 12A7509E12 12C2590G08 12C2590G09 12A7500E22 12 6229 10TA Service Manual RECOMMENDED SPARE PARTS LIST Vogt Model P18FXT Tube Ice Machine DESCRIPTION Freezer pressure switch Thawing timer CR Relay 208 230v 50 60hz PF Contactor 208 230v 50 60hz CU P
18. Press the SET button to set the Set point S1 will be blinking Use the up or down 4 key to set the temperature at 38 F 4 Press the SET button to set the Differential DIF 1 will be blinking Use the up or down Y key to set the differential at 2 F 5 Select between C1 Cooling mode and H1 Heating mode Use the up or down Y key to select C1 Machine will shut off when temperature drops to 38 and come on when temperature reaches 40 Note The sensor will automatically exit the programming mode if no keys are depressed for a period of thirty seconds Any settings that have been input to the control will be accepted at that point DIGITAL TEMPERATURE READING A SENSOR SENSOR POWER CONNECTION CONTROL CIRCUIT CONNECTION FIGURE 3 9 Electronic Thermostat Note If damaged the sensor can be replaced without replacing entire unit Replacement sensor part 12A 2117G0901 Electronic temperature control part 12A 2117G09 Sensor cable can be extended up to 400 feet For more information consult Tube Ice Technical Service Department 6 15 05 10TA Service Manual 3 15 INSTALLING YOUR TUBE ICE MACHINE IMPORTANT Be sure to follow the wiring schematic and electrical specification table when incorporating overloads This is necessary to provide proper protection for the Tube Ice machine and its component parts
19. average 2 Reverse cutter direction 3 Reverse deflector Two people should normally accomplish this conversion process in 6 8 hours or less There must be ample room around the machine for the water tank removal It is recommended that you have good quality water when attempting to produce crushed ice If the ice is opaque and cloudy it is subject to clog the cutter mechanism restrict ice discharge and bind the cutter Also you should not attempt to produce crushed ice when the make up water temperature is below 50 F 10 C Colder water can cause a build up of ice fines in the tank and eventually result in short cycling Crushed Ice Cutter 126413B Gear Reducer 5 1 12A4030R 14 Crushed Ice Cutter Motor 3 4 HP 1140 1000 RPM 12A2900M0601 60hz 12 2900 0603 50hz FIGURE 9 17 Cutter Parts crushed ice option 10TA Service Manual 10 1 OPTIONS AND ACCESSORIES 10 Options and Accessories 8 1 07 10 Service Manual 10 2 OPTIONS AND ACCESSORIES Power Monitor Model EAC 8002 Vogt Tube Ice machine models are available from the factory with a three phase line voltage power monitor with LCD display The units are also available for after market or retrofit installation These units monitor line voltage inputs from 190 to 610 volts and provide protection against line voltage variances which can damage or destroy the compressor motor Features include automati
20. being open during the freeze cycle allows the liquid to be metered by the float switch as the valve opens and closes in response to the refrigerant level in the freezer Wet refrigerant floods the evaporator and is in contact with the outside of the ice making tubes in which water is being circulated The heat contained in this water passes through the wall of the tubes lowering the temperature of the water causing it to freeze and form a long tube of ice that adheres to the inside of each of the freezer tubes The flowing water keeps the accumulated ice clear by washing separated solids down into the sump area of the water tank The wet suction gas leaves the freezer and any remaining liquid droplets are removed by the accumulator and suction line heat exchanger The dry gas enters the compressor and is compressed then discharged to the condenser completing the cycle As the ice is formed in the freezer the suction pressure steadily reduces until it causes the freezer pressure switch to close initiating the harvest period During the harvest period the thawing gas solenoid valve the D valve is open allowing the warm high pressure gas to enter the freezer This heat melts a thin film from the outside of the ice reducing the diameter and letting it fall free from the freezer tubes This period lasts approximately 2 1 2 minutes Refrigerant Charge Included with the machine is the required charge approximately 500 lbs of R
21. further cleaning is not necessary It is useless to try and get a bright copper surface on the inside of the tubes They will 7 6 IOTA Service Manual MAINTENANCE discolor almost immediately in service and the condenser has been designed with an adequate reserve for moderate fouling on these surfaces If however a rough coating remains inside the tubes after flushing and wiping further cleaning is desirable The color of this coating varies with water conditions but roughness indicates cleaning tools should be used Any type tool to be considered should be tried first on a piece of copper tubing held in a vise or flare block Nylon brass or copper brushes are recommended If any flakes of copper appear or if score marks are made inside the tube the tool should not be used Never use anything with sharp or rigid edges which could cut into the copper tubing Lubrication Compressor When starting and charging the unit the oil sight glass 33 in the crankcase of the compressor should be watched carefully for the first hour to make certain the proper lubrication is being maintained The oil may become low in the crankcase on an initial start up if electrical current has been interrupted to the machine thus de energizing the compressor crankcase heater Before starting the machine again the heater should be energized for a time period of at least two hours to evaporate refrigerant that may have condensed in the crankcase during the shut
22. tubes valves 3 2 10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE Water Cooled Connections Note Water regulator valve is not installed on condenser when shipped from the factory Installed water regulator valve on condenser water inlet connection bottom connection on condenser Connect the condenser water out line to the top connection on the condenser 2 1 2 Condenser Water Outlet E H H DR 2 Condenser Water Inlet FIGURE 3 1 Water Cooled Condenser Connections Cooling Tower For water cooled machines only When selecting a cooling tower careful attention must be given to operating wet bulb conditions It is advisable to check with your local cooling tower distributor for their recommendations based on actual operating conditions in your area An average wet bulb of 78 F is typical in the U S but many localities have design wet bulbs as low as 72 F or as high as 82 F The cooling tower water pump must be capable of delivering the required volume of water through the condenser Due to cooling tower location and pressure drop through water lines and water regulating valves the pump must be sized for each installation Refer to TABLE 11 4 for condenser water requirements The water piping for the cooling tower and the installation of the pump must be in accordance with the manufacturer s instructions Proper water treatment for the prevention of mineral and foreign matter accumulation in the condense
23. MNOO T V LO I Connections and Space Diagram Air Cooled Machine 6 15 05 10TA Service Manual 3 4 INSTALLING YOUR TUBE ICE MACHINE LNOYH HGdIS AVAA 8 Srl z _ 01 TI 1 7 7 w HOVdS 77 INSHIOLIAOS Z 2 qa H Al ll x PF LIE 2 X B c gt E M 8 SSH2OV ANVL SS 48 9 E Z Ar A zi 7 S 2 SDN VHOSIG TOI M SSHOOV YOSSHYdNOD LHOTA NO WOANWININ XNVIWHLVA 1 NOLLOdNNOO x h YALVM ELI o 2 LATLAO YALYM d LAINI ALVA 2 NHSNHONOO d f Y SIS WU e 7 i Y alaa la u8 L 11 A SSHOOV ANV NOLLVTIVLSNI Le IDIAINIIN ZI A Y n usss S8HSNHONOO QQ AA AN AONVAVATO 08 FIGURE 3 2B Connections and Space Diagram Water Cooled Machine 6 15 05 6 15 05 IOTA Service Manual 3 5 INSTALLING YOUR TUBE ICE MACHINE Wiring and Electrical Connection WARNING Only service personnel experienced in refrigeration and qualified to work with high voltage electrical equipment should be allowed to install or work on the Tube Ice machine WARNING Refer to TABLE
24. PORT OPEN SUCTION PORT CLOSED FULL CAPACITY REDUCED CAPACITY SCHEMATIC OPERATION OF INTERNAL UNLOADER VALVE FIGURE 9 11 Copeland Compressor Unloader Valve Loaded Operation during freeze This capacity control valve is controlled by an electric solenoid When the solenoid is de energized the valve loads the cylinder bank 2 cylinders as shown in the above figure Unloaded Operation during thaw only During the thaw cycle the solenoid coil is energized The needle valve is seated on the upper port and the unloading plunger chamber is exposed to discharge pressure through the discharge pressure port The differential between discharge and suction pressure forces the plunger down sealing the suction port in the valve plate thus preventing the entrance of suction vapor into the unloaded cylinders 9 16 10TA Service Manual SERVICE OPERATIONS Circulating Water Pump Motor Part No 12 4020601 60hz 12A4020G08 50hz The motor bearings are prelubricated and sealed They require no further lubrication The pump should operate with the water level above the impeller housing The pump is equipped with a mechanical seal that is self adjusting and requires no lubrication However the pump should not be operated unless circulating water The pump manufacturer recommends that a mechanical seal be kept as a spare When ordering a seal specify pump size type serial number and manufacturer s name as indicated on the nameplate e
25. Service Manual 10 4 OPTIONS AND ACCESSORIES PASSWORD Mode In this mode the SETUP key has an alternate function of ENTER PASSWORD and the CLOCK key has an alternate function of CANCEL PASSWORD The first time you choose YES to the Using Password parameter you will be asked to enter the password In order to enter the password use the UP amp DOWN key to change the number selected by the display cursor To move to the next number press the ENTER PASSWORD SETUP key To correct a wrong entry press the CANCEL PASSWORD CLOCK Key This procedure is valid when entering a new password entering the password to change parameters or to erase the fault registers Once the password has been entered it will remain active while you are using the keyboard interface If the keyboard is inactive for more than 3 minutes the password will be blocked If you need to change any parameter you will be asked to enter it again If you are using a password and want to change it go to the SETUP mode and enter YES to the Using Password parameter You will be asked to enter a new one Troubleshooting SYMPTOM DISPLAY LED s SOLUTION Load will not energize LOAD LED not lit Check control input LED s blink periodically Occasional Blinking Line voltage too low and or phase missing but unit never comes up Flash Control LED does not go CONTROL LED Control input is very sensitive Insure out when control is off always
26. Valve 4PS Dual High Low Pressure Switch 37 Oil Charging Drain Valve 5M Cutter Motor 39 Water Tank Drain Valve 5R Gear Reducer 40 Automatic Water Tank Blowdown 6 Water Pump 41 Condenser Water Regulator W C Machines 7 Water Tank includes cutter assembly 41 Condenser Pressure Control A C Machines 8 Water Distributing Chamber 43 Strainer 12 Make Up Water Float Valve 44 Receiver Drain Valve 13 Heat Exchanger 46 Filter Drier 14 Oil Separator 48 Muffler 15 Condenser 50 Receiver Safety Valve 15R Receiver 51 Freezer Safety Valve 16 Thawing Chamber 53 Cold Weather Solenoid Valve X A C Machines 17 Expansion Valve 55 Discharge Line Stop Valve For A C Machines 18 Thawing Gas Solenoid Valve D 56 Freezer Pressure Switch 185 Thawing Gas Pressure Switch 58 Liquid Outlet Valve King Valve 19 Capillary Bypass 59 Receiver Purge Valve 20 Liquid Feed Solenoid Valve 1 69 Freezer Pressure Stop Valve 21 Liquid Feed Solenoid Valve 2 70 Oil Return Stop Valve 22 Float Switch 88 Accumulator Heat Exchanger 23 Condenser Water Inlet W C Machines 90 Thawing Gas Stop Valve 23 Make Up Water Inlet 3 4 91 Receiver Liquid Return Stop Valve 24 Condenser Water Outlet W C Machines 94 Compressor Oil Pressure Safety Control 25 Water Tank Drain Connection 1 FPT 101 Check Valve 28 Refrigerant Charging Valve Piping Nomenclature 10TA Service Manual 8 1 2007 DISCHARGE o Go
27. allowed to adjust these settings by pressing the CLOCK key again If you choose to adjust the clock settings the display cursor and the LED will start blinking Use the UP amp DOWN key to increase or decrease the value selected by the cursor To go to the next setting press the CLOCK key The new date and time will only be updated if you complete the adjustment of all settings Otherwise the old date amp time will return 8 1 07 8 1 07 10 Service Manual 10 3 OPTIONS AND ACCESSORIES FAULT Mode To enter this mode press the FAULT key once Using the UP amp DOWN keys you can choose between recalling the fault registers executing a Manual Reset or executing an Erase Fault Registers command When you enter the FAULT Mode you can recall the fault registers from most recent to the oldest by pressing the UP key The EAC 8002 will show all faults in chronological order followed by date and time when the fault occurred On the second line a message will describe the fault When you see the more Faults message you have reached the last stored register By pressing the DOWN key once after you enter FAULT mode you will see Manual Reset To execute a manual reset press the FAULT key again You will be asked to confirm the command Use the UP amp DOWN keys to make your selection and press the FAULT key to execute By pressing the DOWN key twice after enter FAULT mode you will see Erase Fault Regs To exe
28. and Drain Water Cooled 3 1 3 2 Water Supply and Drains Air cooled 3 1 3 4 Water Tank Water Tank 9 18 Water Usage Condenser 11 5 Water Usage Make up 11 5 Wiring and Electrical Connection 3 5 Wiring Schematic Air Cooled Condenser 3 12 Wiring Schematic All Voltages 50 60 Hz 6 5 X X Valve 4 2 2 8 1 07 12 3 INDEX
29. and are known to be a source of leaks in refrigeration systems A second advantage of Sentronic is in the use of a precise electronic clock for the two minute time out circuit Traditional mechanical controls use resistance heaters to provide the time to trip in the event of low oil pressure 208 volt systems low ambient temperatures or brown out type conditions cause the heater output to be reduced thus increasing the time out period from two minutes to three or four minutes when low oil pressure conditions exist With the electronic clock the time out will always be the same As a result of the elimination of the capillary tube measuring system and a more precise timing circuit Sentronic will improve the overall reliability of the refrigeration system As in the past all new and replacement Copelametic compressors equipped with oil pumps require the use of a Copeland approved oil pressure safety switch Failure to use an approved oil pressure safety switch will be considered as misuse of the compressor and can adversely affect warranty replacement of the compressor should a lubrication connected failure occur Sentronic Oil Safety Control Entire Unit Part 12 2117 05 Sentronic Safety Sensor Only Part 12A2117A0501 FIGURE 9 7 Sentronic Oil Pressure Safety Control Sentronic Sensor The same oil pressure sensor is used for all Sentronic Oil Pressure Controls It mounts directly into the oil pump The sensor measures oil
30. charging valve 28 is provided for this purpose Be sure to follow all local and federal regulations regarding the handling of refrigerants and their illegal emission into the atmosphere CAUTION Check the refrigerant level after the machine has operated for a few cycles It should be slightly above the minimum operating level as indicated on the receiver a few minutes prior to start of a thawing period If this level is low at this time sufficient refrigerant should be added to the system to raise the level above this point Add only a small quantity 10 lbs or less at a time and operate the machine several cycles to check the level before adding additional refrigerant Refrigerant may be added as a liquid through the charging valve 28 only while the machine is operating It is important that no air or other non condensable gas enter the system when charging refrigerant into the unit It is also possible to check the refrigerant level by pumping machine down See 9 12 When the machine is pumped down a liquid level should be observed in the gage glass on the receiver Refrigerant Charging Procedure 1 Make connection between charging valve and refrigerant cylinder using hose or pipe suitable for R 22 or R 404a service See instruction card attached to refrigerant cylinder 2 Open valve on cylinder and purge air out of charging line at the charging valve connections 3 Open charging valve 4 Refrigerant can be added only du
31. freight line s agent Any repair work or alteration to the machine without the permission of Tube Ice LLC can void the machine s warranty The machine was shipped with a full charge of R 22 stored in the receiver Visually check all lines for mechanical damage If a leak is suspected check all joints with a Halogen Leak Detector leaks should be reported to the Tube Ice LLC to obtain authorization for repair CAUTION The approximate weight of the machine is 4900 pounds Always use equipment with adequate load carrying capacity CAUTION The machine frame has lifting lugs at each corner in the top for eyebolts and hooks to be used for lifting purposes if desired Lifting lugs should be used whenever possible CAUTION The Tube Ice machine is top heavy Secure to avoid tipping CAUTION If a forklift is used make sure its capacity is sufficient The forks must be wide enough apart to prevent tipping sideways and must extend beyond the extremities of the frame base structure The machine needs to be bound in place to prevent tipping Safety Valves Two safety pressure relief valves are an integral part of the packaged Tube Ice machine One is located in the low side of the system on the freezer and one is in the high side of the system on the receiver Vent each of the pressure relief valves to the atmosphere in such a manner as to comply with local and national codes Machine Room The machine must b
32. motor bearings 10 Service Manual 7 9 MAINTENANCE For The Manager Who Depends Upon This Machine For Efficient Operation Preventive Maintenance simply means that you or a delegated employee makes a daily visual check of your Tube Ice machine Here is what to look for and why Daily checklist 1 Is the machine running or is the bin full 2 Bin doors kept closed 3 Thermostat bulb in bracket 4 Ice quality clarity and uniformity 5 Does all ice discharge during harvest 6 Cleanliness 7 Unusual noises Why When you make these simple observations on a daily basis you insure the smooth production of ice for your facility When you are aware of the proper operating conditions and observe them on a daily basis changes in these conditions can alert you to changes in the operation of the machine which may require maintenance long before a service situation arises An ounce of prevention is worth a pound of cure Note To Manager or Owner The following page is a complete Preventive Maintenance Schedule that should be performed each 90 days The Preventive Maintenance page may be copied and given to your service person It should be signed dated and returned to you for permanent record 8 1 07 7 10 10TA Service Manual MAINTENANCE PREVENTATIVE MAINTENANCE FORM This form can be removed and duplicated for record keeping Date Model Serial The following service performed and checked Hour me
33. on control voltage 2 volts for off condition System trips out on low or FAULT LED flashes Check normal line voltage using READ high line voltage due to fault feature Re adjust voltage range as required Output relay never turns Control Mode setting is OFF Press on SETUP to get to Control Mode then mode to EXTERNAL TABLE 10 2 Power Monitor Parameters IOTA Service Manual 11 1 TABLES amp CHARTS 11 Tables amp Charts 8 1 07 11 2 10TA Service Manual TABLES amp CHARTS P18FXT SPECIFICATIONS 208 230 Volt 3 Phase 60Hz Tube Size inches cm 112 Gs Rota FLA Waco im m j Total FLA AirCooled 19 19 19 EE makeup gpm mH condenser gpm mH omg j A TS EE E AC condenser outlet 11 8 Compressor HP KW FLA 30 22 4 105 30 22 4 105 30 22 4 105 TowerPump operating weight lbs Kg 1100 499 1100 499 1100 499 1 Nominal capacity is based on 70 F makeup water 100 F condensing temperature 70 F ambient and 0 blowdown 2 FLA for 460 volt models is approximately 1 2 that of 230 volt models Total FLA does not include cooling tower 3 Makeup water is maximum value and includes 10 gallons per cycle blowdown 4 Condenser flow rate is for 85 F entering water temperature and 100 F condensing 5 Tower sized for 80 F wet bulb temperature 6 Recommended air cooled condenser is ba
34. prevent the same cause from reoccurring Symptom Machine Won t Run Freeze up Due To Extended Freeze Period Freeze up Due To Ice Failing To Discharge Poor Ice Quality Low Ice Capacity Low Compressor Oil Level High Head Pressure Water Cooled Machines High Head Pressure Air Cooled Machines SYMPTOM Machine won t run POSSIBLE CAUSE POSSIBLE REMEDY Power failure Intermittent power interruption Compressor motor overload CMS OL trips Compressor cylinder head temperature switch TS OL trips One of the 2 5 amp control circuit fuses FU I or FU 2 in the control panel burnt out High Low safety pressure switch tripped Page 8 1 amp 8 2 8 2 8 3 8 3 8 4 8 4 8 5 8 5 Check electrical fused disconnect or circuit breaker supplying power to the machine If power has been off make sure the compressor crankcase heater is energized the crankcase is warm and there is no liquid refrigerant in the crankcase prior to running the machine Push the Start button which will initiate startup in a thawing cycle Check for a loose connection on all motor contactor and compressor terminals which could have caused excessive amp draw Check amperage power supply and head pressure The thermal switch will reset automatically after the motor has cooled sufficiently Excessive temperature may be caused by gas leakage between suction and discharge port of the compressor Check for broken cylinder head gasket or
35. to the Off position T Controls the time of the thawing period TB Numbered for multiple wire connections and ease of troubleshooting TB1 Customer connections for remote Air Cooled condenser TB2 Customer connections for auxiliary contacts on cutter pump and compressor contactors TABLE 6 2 Description of Control Panel Component Function 8 1 07 10TA Service Manual 6 5 ELECTRICAL CONTROLS r_s l LL 4 FIGURE 6 3 Electrical Schematic All Voltages 50 60 Hz 8 1 07 6 6 ELECTRICAL CONTROLS 8 1 07 COMPRESOR TERMINAL SENSORS BROWN BLACK 51 52 53 Electronic Motor Protector Module T2 1 M2 1 NOTE ELECTRONIC OVERLOAD PROTECTOR MODULE USED ON 20HP OR LARGER COPELAND DISCUS COMPRESSORS COMPRESSOR P18XT DX 11 208 230V 105 0A 60HZ 460V 3PH 52 5A 60HZ 55 200V 125 0A SOHZ 580 400 3PH 62 5 50HZ FIGURE 6 4 Compressor Schematic Detail All Voltages 50 60 Hz 10TA Service Manual 8 1 07 10 Service Manual 7 1 MAINTENANCE 7 Maintenance Ice Making Section The ice making section of the Tube Ice machine should be cleaned at least twice a year more often if water conditions cause mineral build up Use an approved food grade ice machine cleaner The water pump is used to ci
36. valve assemblies Replace broken or defective parts Restart the machine and check motor amps and temperature of compressor body Check compressor crankcase heater coils of relays contactors starters solenoid valves and thawing timer for a ground Repair or replace any defective part and replace fuse Make sure there is no liquid refrigerant in the compressor crankcase prior to re starting the machine If the machine stops by low pressure cut out the switch will reset automatically when the pressure raises to the cut in setting If it stops by high pressure cut out the switch will have to be manually reset after the pressure drops below the cut in setting Check switch settings and push the Start push button to start the machine in a thawing cycle Check the head pressure during the next freeze cycle See FIGURE 9 4 Section 9 High Low Pressure Switch 8 2 10TA Service Manual TROUBLESHOOTING SYMPTOM Machine won t run CONT POSSIBLE CAUSE POSSIBLE REMEDY Low oil pressure switch tripped If the machine stops by low oil pressure cut out the switch will have to be manually reset Check the crankcase oil level Restart the machine by pushing the Start push button Check the oil level and net oil pressure net oil pressure pressure reading at the oil pump end bearing housing minus suction pressure The oil level should be 1 4 3 4 level in the glass If above 3 4 drain some oil out See page 9 9 Sec
37. 1 5 Assembly Water Cooled Right Side View gi 10 Service Manual FREEZER Q FREEZER PRESSURE STOP VALVE 69 SUCTION ACCUMULATOR 88 FLOAT SWITCH Q2 LIQUID FEED SOLENOID VALVE VALVE 20 HAND EXPANSION VALVE 17 FREEZER REFRIGERANT CHARGING VALVE Q8 LIQUID FEED SOLENOID VALVE A2 VALVE 21 FILTER DRIER 46 8 1 07 10 Service Manual CONDENSER WATER REGULATING VALVE 41 SAFETY RELIEF VALVE 50 RECEIVER 15R RECEIVER SIGHT GLASS 30 THAWING GAS SOLENOID VALVE D VALVE 18 RECEIVER DRAIN VALVE 44 GEAR REDUCER GR MAKE UP WATER FLOAT VALVE 12 A Sg Ss E g FIGURE 1 6 Assembly Water Cooled Left Side View 1 9 INTRODUCTION H H H H OIL SEPARATOR 14 CUTTER MOTOR 5 1 2 MAKE UP WATER CONNECTION 8 1 07 10 Service Manual 2 1 RECEIPT OF YOUR TUBE ICE MACHINE 2 Receipt Of Your Tube Ice Machine Only service personnel experienced in refrigeration and qualified to work with high voltage electrical equipment should be allowed to install or work on this Tube Ice machine WARNING Inspection As soon as you receive your machine inspect it for any damage If damage is suspected note it on the shipper s papers 1 the trucker s Bill of Lading Immediately make separate written request for inspection by the
38. 2 Checklist Installation Review 3 15 Chemical Cleaning 7 5 Circuit Breaker Control 6 2 6 3 6 4 Circulating Water Pump Motor 9 16 Clean Off Ice Switch 6 1 Cleaning Procedure 7 1 Compressor m 7 6 Compressor Crankcase Heater 9 10 Compressor Lubrication 7 6 Compressor Motor Burnout 9 13 Compressor Unloader 9 15 Compressor Contactor 6 2 6 3 6 4 Compressor Motor Protection 9 6 Condenser Cleaning 9 5 Condenser Fan Contactor FC 6 2 6 3 6 4 Condenser Fan Switch Condenser Piping Cold Weather Valve Kit 3 9 Condenser Water Usage 11 5 Condenser Air cooled Cleaning 9 5 Condenser Air cooled Heat Rejection 3 8 Condenser Pressure Switch CPS 9 5 Condenser Water Cooled 3 2 7 4 Control Circuit Protection
39. 3 Section 9 Freezer Pressure Switch and TABLE 11 6 Section 11 Operating Vitals Check compressor amps during harvest A noticeable drop in amperage should occur Check unloader solenoid coil If coil is okay replace unloader head assembly Perform a cleaning procedure as well as removing the freezer cover and cleaning the water distributors Adjust continuous blowdown Check water pressure 30 PSIG is recommended minimum Check for a water line restriction partially closed valve or defective make up water float valve Make sure the water tank drain valve is closed Water pump rotation wrong direction Check rotation in relation with arrow on pump housing and reverse two wires at the motor if necessary Check refrigerant level mark on the receiver and on the painted portion of the gage glass guard Perform pumpdown if necessary Be sure to keep the gage glass cocks closed when finished checking the level Check for proper operation of the siphon vacuum break valve and restrictions or traps in the water tank drain assembly 8 4 10TA Service Manual TROUBLESHOOTING SYMPTOM Low ice capacity POSSIBLE CAUSE POSSIBLE REMEDY Low refrigerant charge Check for and repair leaks and add refrigerant Restriction in liquid line Check for a partially closed valve or an obstruction at the drier strainer solenoid valve or expansion valve The liquid line will normally have frost on the downstream side of a restrict
40. 3 0 396 0 33 44 628 743 31 3 136 19 383 0 406 0 35 2 774 138 20 I 392 0 416 0 36 9 80 5 140 20 402 0 426 0 38 8 83 8 142 2 412 0 436 0 40 7 87 0 144 2 423 0 447 0 42 7 77 6 904 42 0 434 0 458 0 44 7 93 9 148 372 3 398 9 277 0 444 0 468 0 46 7 97 4 45 5 150 449 0 479 0 TABLE 11 7 All pressures are in Ibs in gage psig 8 1 07 11 8 10TA Service Manual TABLES amp CHARTS REFERENCE INFORMATION CONVERSION FACTORS English to Metric To Convert Multiply by Area 9 2903e 2 i 6 416 e 4 Joule J 1054 48 BTU Hr 2546 2 1 34 Pressure Ibf ft Paschals 47 88 Ibf in psi Paschals 6894 76 in Hg psi 0 491 in H O 0 03612 Temperature 5 9 32 9 5 32 Volume E 2 8317e 2 gal U S 3 7854 3 ft Bvd 5 7 48 11 8 CONSTANTS Specific heat of Water 1 F Specific heat of Air 4 19 kJ kg 0 24 F Tube Ice Tube Ice Density 32 35 Ibs ft Water Water Sensible Heat Heat 1 BTU Ib F Ice Melting UI IME 1 Ton Refrigeration 12 000 BTU hr Atmospheric pressure 14 7 psia Weight of Water 62 4 Ibs ft 8 33 lbs gal 12013 Ib day Weight of air 0 0749 Ibs ft 0 0100 Ibs gal Kilowatt 1 34 horsepower TABLE 11 9 8 1 07 8 1 07 10 Service Manual 12 Index A A Valves 4 1 5 1 Accumulat
41. 3 2 below to properly size wiring connections A fused disconnect must be provided near the Tube Ice machine Connect 3 phase power to terminals L1 L2 L3 for operation of the Tube Ice machine and its controls Rotation checking of cutter motor and water pump is required see following section Also if one leg of the 3 phase power is higher or lower Wild then it should be connected to terminal L2 Connect the Ground wire to the Ground lug provided GROUND MAIN MACHINE POWER INCOMING POWER TO BE CONNECTED TO TERMINALS L1 L2 AND L3 AT THE COMPRESSOR MOTOR CONTACTOR POWER CONNECTIONS Q CONNECTED TO TERMINALS B7 B8 AND B9 AT THE TERMINAL BLOCK TB2 B7 89 AIR COOLED CONDENSER Ll L2 L3 KZ CONTROL CONNECTIONS cc CONNECTED TO TERMINALS 11 22 CU P AT THE TERMINAL BLOCK TB2 BT AUX CONNECTIONS BL CUTTER MOTOR PUMP MOTOR COMPRESSOR AT THE TERMINAL BLOCK TB3 FIGURE 3 3 Control Panel Power Connections Water Cooled Air Cooled Min Ampacit 208 230 3ph 60 Hz 112 3 138 6 129 3 155 6 Standard Voltages 220 3ph 50 Hz 400 3ph 50 Hz TABLE 3 2 Electrical Specifications 3 6 10 Service Manual INSTALLING YOUR TUBE ICE MACHINE Phase Check CAUTION DO NOT attempt to start machine without priming pump and insuring proper rotation of both cutter and pump Refer to FIGURE 3 1 amp 3 2 space diagram for connection lo
42. 6 10 Service Manual 9 15 SERVICE OPERATIONS Capacity Control Valve Internal Construction A schematic illustration of the internal valve operation is shown in FIGURE 9 11 Part No 12A2110P0907 In the normal full capacity operating position with the solenoid valve de energized the needle valve is seated on the lower port and the unloading plunger chamber is exposed to suction pressure through the suction port Since the face of the plunger is open to the suction chamber the gas pressures across the plunger are equalized and the plunger is held in the open position by the spring When the solenoid valve is energized the needle valve is seated on the upper port and the unloading plunger chamber is exposed to discharge pressure through the discharge pressure port The differential between discharge and suction pressure forces the plunger down sealing the suction port in the valve plate thus preventing the entrance of suction vapor into the unloaded cylinders The seal on the unloading plunger minimizes any leakage in pressure so that a pumpdown cycle may be used with the valve either energized or de energized without excessive compressor cycling NEEDLE VALVE PORT TO DISCHARGE PRESSURE PORT TO SUCTION PRESSURE SEAL UNLOADING PLUNGER SUCTION CHAMBER IN COMPRESSOR HEAD SPRING SUCTION PORT IN VALVE PLATE NORMAL OPERATING CONDITIONS UNLOADED OPERATION VALVE DE ENERGIZED VALVE ENERGIZED SUCTION
43. 72 15912 80 18300 16500 15000 19032 17160 15600 18300 16500 15000 19032 17160 15600 82 17960 16180 14700 18678 16827 15288 17960 16180 14700 18678 16827 15288 83 17790 16020 14550 18502 16661 15132 17790 16020 14550 18502 16661 15132 84 17620 15860 14400 18325 16494 14976 17620 15860 14400 18325 16494 14976 85 17450 15700 14250 18148 16328 14820 17450 15700 14250 18148 16328 14820 86 17280 15540 14100 17971 16162 14664 17280 15540 14100 17971 16162 14664 89 16770 15060 13650 17441 15662 14196 16770 15060 13650 17441 15662 14196 90 16600 14900 13500 17264 15496 14040 16600 14900 13500 17264 15496 14040 Capacity rating based on 70 F ambient conditions 100 SDT temperature Capacity rating is average for the model Individual machines may vary up to 596 above or below Capacity rating is for clear ice production with makeup water containing no more than 200ppm total dissolved solids 50 52 53 54 55 56 58 59 60 62 63 64 65 66 68 69 7 Table 11 3 8 1 07 IOTA Service Manual 11 5 TABLES amp CHARTS Condensing Entering Water Leaving Water Water Flow Pressure Average gpm Drop Total Heat of Rejection L u0 09 280 _
44. Air cooled 4 4 Piping Schematic Nomenclature 4 2 Piping Schematic Water cooled 4 3 Poor Ice 8 3 Power Connection 3 5 Power Monitor 10 2 Preventive Maintenance 7 8 Preventive Maintenance Program 7 8 Preview 1 1 8 1 07 10 Service Manual Principle of Operation 4 1 Pump 9 12 Pump Overload Protection 6 2 6 3 6 4 Pump Contactor 6 2 6 3 6 4 Q R R 22 22 1 2 2 1 5 1 404 5 1 Receipt of Machine 2 1 Receiver 4 1 Refrigerant Charge 5 1 Refrigerant Leaks 5 1 9 13 Refrigerant Removal
45. Anti Seize lubricant to the shaft of the replacement motor Position the shaft key in the motor keyway align it with the reducer key way and install the motor Make sure the key stays in position as shaft is inserted Install the four cap screws to hold the motor in place on the reducer Connect the wires and install the terminal cover Check motor rotation to make sure the cutter turns in the proper direction Reverse two wires at the motor if necessary to change rotation direction Cutter Gear Reducer To remove the gear reducer proceed as follows See FIGURE 9 16 mee SCH 10 11 Turn power off and lockout disconnect Remove motor from reducer Loosen slightly the four bolts and nuts holding the gear reducer in place Remove the four bolts holding the mounting plate to the water tank gear enclosure and remove the reducer and mounting plate from the tank Measure the distance between the top of drive gear and the mounting plate for future reference Remove the three cap screws from the gear and hub and install two 1 4 20 x 2 long all thread set or cap screws in the threaded holes of the drive gear These two screws can be used as jacking bolts to remove the gear from the tapered split hub The split hub can be removed by driving a screwdriver in the split and sliding the hub off the shaft The new gear reducer can then be installed by reversing the removal procedure Be sure the gear and hub is properly positione
46. Control Panel Switch Layout Starting Procedure Initial Start Up NOTE The machine will start in the harvest mode when set to Ice 1 Set the Clean Off Ice selector switch to the Clean position 2 Push the Start button PB2 to start the water pump 3 The pump can be stopped and started by the Stop and Start push buttons Water should be circulated for a minimum of five 5 minutes to prime the pump purge the tubing of air and lubricate the cutter bearing Note If pump is already primed skip steps 1 3 4 When there is good water flow turn the Clean Off Ice selector switch to Ice The machine will then start in a harvest thaw period with the compressor running 5 Atthe termination of the harvest thaw period the machine will begin the freeze period 6 Be sure to observe a minimum of four 4 cycles of ice production to confirm the satisfactory operation of the machine approximate time for four cycles is 60 80 minutes Complete the remaining part of the Warranty Registration Start Up Report upon initial machine start up and return it to Tube Ice LLC 8 1 07 8 1 07 10TA Service Manual 5 3 START UP AND OPERATION Shut down CAUTION The red Stop button should only be used for emergency shutdown For normal shutdown use the Clean Off Ice button CAUTION Set the Clean Off Ice switch to the Off position Do not use the machine d
47. Cooled 8 5 High Head Pressure Water Cooled 8 5 High Low Pressure Switch 9 4 History Tube Ice 1 1 Hub Cutter Drive Gear 9 20 12 2 INDEX 1 Ice Thermostat Location 3 13 Ice Capacity 11 4 Important Safety Notice 1 2 Inspection First Arrival 2 1 Installation 3 1 Installation Review A Checklist 3 14 Introduction 1 1 J K L Low Compressor Oil Level 8 4 Low Ice Capacity 84 Low Pressure Switch 9 4 Lubrication 7 6 Lubrication Compressor 7 6 Lubrication Cutter Gear 7 7 Machine Ratings 50 Hz 35 HP 11 3 Machine Ratings 60 Hz 30 HP 11 2 Machi
48. DENSER FAN MOTOR 1 FAN MOTOR 2 CONDENSER c J _ 2 FAN MOTOR 3 AMBIENT THERMOSTAT CLOSE AT 60 F CONDENSER TS3 FAN MOTOR 4 FIGURE 3 7 Wiring For DD 591 and DD 661 Condenser 3 phase motors Air Cooled Connections See FIGURE 3 2A for connection sizes Follow these procedures to make a tight joint l Silver solder or braze condenser tubing ends to the female Rota lock connectors Remove dust caps if used making sure that component plastic seals are intact Wipe off connector and spud threaded surfaces with a clean cloth to prevent the inclusion of dirt or any foreign material in the system Connector coupling nut should be screwed onto Rota lock spud using the proper amount of torque Amount of Torque 50 60 FT LBS TABLE 3 6 Rota lock Connector Torque Ratings 10 Service Manual 3 13 INSTALLING YOUR TUBE ICE MACHINE Ice Bin Thermostat Sensor Optional An electronic ice bin thermostat may be added to automatically cycle machine operation To assure proper protection for the machine or auxiliary equipment the sensor of the ice bin thermostat must be located so that ice will contact it when the bin is full See FIGURE 3 8 for typical mounting bracket The distance between the top of the ice bin and the sensor allows space for the machine to make an additional discharge of ice AFTER the ice contacts the probe This will vary based on the size of the bin and the ice distribution system employed N
49. FIGURE 3 5 Condenser Field Piping Cold Weather Valve Kit 6 15 05 IOTA Service Manual 3 11 INSTALLING YOUR TUBE ICE MACHINE CONDENSER EQUIVALENT LINE SIZE WORKSHEET Discharge Gas Line O D Fitting Tvpe Number Used Factor Total Globe Valve open Angle Valve open 90 Elbow 45 Elbow Tee Feet of Straight Copper Used Total Fitting Factor Total Equivalent Feet Copper Tubing L 11 8 O D 13 8 O D 42 21 4 2 2 8 95 95 009 turn through 6 8 Tee straight through 2 25 228 35 TABLE 3 5 Equivalent Feet Due To Friction 57 28 5 22 12 3 5 f RI Oxy BEST BETTER AVOID FIGURE 3 6 Minimum Traps For Discharge Lines Note Each recommended line size is based on use of Type L copper tubing at a maximum equivalent distance of 150 feet See TABLE 3 5 for equivalent feet of valves and fittings 6 15 05 3 12 10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE 6 15 05 Air Cooled Condenser Wiring FIELD DISCONNECT FIELD DISCONNECT SUPPLIED BY CUSTOMER SUPPLIED BY CUSTOMER CONDENSER CONTROL PANEL CONDENSER FAN MOTOR 5 AMBIENT THERMOSTAT N O SOLENOID CLOSE 35 TSI AMBIENT THERMOSTAT CLOSE AT 50 F FAN CONTACTOR TS2 CONDENSER CON
50. FIGURE 9 5 nds 9 5 SAA a RA 9 5 Air Cooled Condenser 9 5 Compressor Motor Protection Electronic sees nene entente 9 6 High Potential Testing so e EAR 9 6 TroubleshOotn e ER EE 9 7 Electronic Module and Compressor Terminal Board Connections FIGURE 9 6 Oil Pressure Safety Control Sentronic Oil Safety FIGURE OH RRE 9 9 NS A te mU UDIN dnte st 9 10 Oil Separator FIGURE O Bi A tU 9 10 Compressor Crankcase Heater 9 10 10 Service Manual TABLE OF CONTENTS 9 SERVICE OPERATIONS cont Control Circuit Protection oon ep tite dere Th wing Timer FIGURE 9 0 A Thawing Eimer La DAE Pump db gp RA oe Lea nates wad oad e Removal Of Refrig rant From Machine one eee a eet ep din Refrigerant d Io eb e ei i e ee ei pto t e Ses ipie epe ra tetas Non Cond nsabl Gases u ERR RE ti va qon Compressor Motor B tnoUt 1 oret tette tr tr he e Lee enn e vete to et Solenoid Valves t RU RR ta ei e ira a RO D eoe et qe Thawing Gas Solenoid Valve D Valve FIGURE 9 10A nennen Liquid Feed Solenoid Valve 1 amp A2 Valve FIGURE 9 10B Capacity Control Valve Compressor Copeland Compressor Unloader Val
51. GURE 25 1 e ence en aia 5 2 Shut down Procedure eb ee b reb et i pcr be 5 3 Operating MP AO D det 5 3 Adding Refrigerant ces urere Gt oaa RES AR HRS RU rece e ER GR 5 4 6 ELECTRICAL CONTROLS amp THEIR FUNCTIONS ControlPanel Cover On FIGURE 0 15 eere dE ENEE 6 1 Control Panel Cover Removed FIGURE 6 2 6 2 Control Panel Components and Part Numbers TABLE 6 1 6 3 Control Panel Part Descriptions TABLE 6 4 Electrical Schematic Voltages 50 60 Hz Across Line Start FIGURE 6 3 Compressor Schematic Detail All Voltages 50 60 Hz FIGURE GA 7 MAINTENANCE Ice Making eL s Ud ue dete i de Ae RR Ee 7 1 ie widow 7 1 Sanitizipe PLOCE EE 7 2 Water Distributors na e E RERE E A sa Number of Water Distributors Per Tube Size TABLE 7 1 Average Hole Size In Tube Ice TABLE 23 7 3 A qu 7 3 Freezer ES 7 3 Water Cooled EE 7 4 CEA A Rees 7 4 KI Lut EE 7 4 Chemical Cleaning eere A A 7 5 Mechanical Cleaning 7 5 Dibra cations E 7 6 Lubricdtion Compressor nu n U u ii 7 6 Compressor Recommended Lubricants TABLE WI 7 6 Cutter Gear Redu cer Lubrication i e teer ren eei ed 7 7 Pr ventive 7 8 10 Service Manual TABLE OF CONTENTS Page No 7 MAINTENANCE cont For WE 7 9 Preyentive Maintenance Form uuu
52. GURE 9 15 Cutter Parts cylinder ice 8 21 06 9 20 10TA Service Manual SERVICE OPERATIONS 12A2240A1108 HEX NUT 5 16 S S Boc t 12A2250B108 we pis 12 4030 12 LOCK WASHER 5 16 S S GEAR REDUCER GEAR REDUCER MOUNTING PLATE BOLTED TO CUTTER HOUSING 1 12 2250 108 WASHER 5 16 S S d 124221561108 CAP SCREW 5 16 X 3 4 HEX HEAD S S 19T2615D01 4 DRIVE GEAR WITH TAPERED HOLE 12A2215F1112 02 12A2250B107 AP SCREW 1 4 X 1 1 4 HEX HEAD S S SE LOCK WASHER 1 4 S S 12 2160 0101 SPLIT FOR CUTTER DRIVE GEAR FIGURE 9 16 Cutter Drive Parts 8 21 06 8 21 06 10 Service Manual 9 21 SERVICE OPERATIONS Crushed Ice Production Your 10TA Tube Ice machine is capable of producing crushed ice with no loss of capacity However there are certain changes to be made in order to convert to crushed ice production Add Cutter Assembly 126413B 2 Cutter Motor 3 4 HP 60hz 12 2900 0601 208 230V 460V 3 2 1 6A b 50hz 12A2900M0603 190 380V 4 2 2 1A 3 Gear Reducer 5 1 Ratio 12A4030R14 4 Motor Starter a 60hz 208 230V machine 12A7530E55UL 2 5 4 0 460V machine 12A7530E54UL 1 6 2 5A b 50hz 200V machine 12A7530E56UL 4 0 6 3A 400V machine 12A7530E54UL 1 6 2 5A Change 1 Raise the freezer pressure switch setting to make ice 3 16 thick
53. Motor Starter 1 0 1 6A 400V 50hz 12A7530E54UL Cutter Manual Motor Starter 1 6 2 5A 200 208 230V 50 60hz ET 12B7503E17 Timer Elapsed Panel Mount 220V 50Hz 12B7503E18 Timer Elapsed Panel Mount 220V 60Hz Condenser Fan Contactor 23 Amp 3 Pole 1 N C Aux Contact EE Coil e E d Only 12A7530E57UL Fan Manual Motor Starter 6 5 10 0A 400 460V 12A7530E58UL Fan Manual Motor Starter 10 0 16 0A 200V 5067 12A7530E59UL Fan Manual Motor Starter 18 0 25 0A 208 230V 6067 FPS 12A2117E04 Freezer Pressure Switch 12A7516E23 Contactor 9Amp 3 Pole with 1 N O Aux 208 240V Coil P 12A7530E55UL Pump Manual Motor Starter 2 5 4 0 400V 460V 50 60hz 12A7530E56UL Pump Manual Motor Starter 4 0 6 3A 208 230V 60hz 12A7530E57UL Pump Manual Motor Starter 6 5 10 0 200V only PB1 12A7500E57 Stop Push Button Red 12A7500E76 Contact Block Mounting Latch 1 N C PB2 12 7500 56 Start Push Button Green 12A7500E73 Contact Block Mounting Latch 2 N O PF 12A7516E23 Power Failure Contactor 9 Amp 3 Pole 1 N O Aux Contact 208 240V Coil SS 12A7500E61 Selector Switch 3 Position 12A7500E77 Contact Block Mounting Latch 2 1 T 12A7503E22 Thawing Timer Delay On Make 100 240V 12A7503E39 Timer Base 8 Pin Guarded Terminal TB1 19T7501E03 Terminal Block Assembly TB2 N A Terminal Block for Air Cooled Condenser TB3 N A Terminal Block Connections for Customer TABLE 6 1 Control
54. Panel Components and Part Numbers See FIGURE 6 1 amp 6 2 6 3 6 4 10TA Service Manual ELECTRICAL CONTROLS Description of Component Function Auxiliary trip indicator for manual motor starters Switches when cutter or pump motor starter trips CB Overload and short circuit protection for control circuit and crankcase heater CC Provides power to the compressor motor Continuously energized during freezing and thawing Auxiliary contacts control main power for control circuit components crankcase heater control relay and harvest timer CR Controls sequencing of Freezing and Thawing circuits Energized during thawing period CU Cutter Motor Starter Manual motor starter and contactor Starts and stops cutter motor Provides short circuit and over current protection Stops cutter motor and ice machine in the event of a mechanical or electrical malfunction that results in excessive motor amperes Indicates hours of machine operation Energized when compressor is operating FC Cutter Motor Starter Manual motor starter and contactor Cycles the fan motor s of air cooled condenser on and off Activated by the condenser pressure switch Air cooled Machines ONLY Provides short circuit and over current protection Stops fan motors in the event of a mechanical or electrical malfunction that results in excessive motor amperes FPS Regulates the ice thickness by reading freezer pressure and initiatin
55. Starter 208 230v 50 60hz Compressor Contactor 208 230v 50 60hz Cutter motor 1 2 HP 3 ph Make up water float valve Cutter bearing Gasket for freezer cover Gasket for water tank Crankcase heater 100W Insert type Copeland Discus Compressor Suction pressure gage Discharge pressure gage Float Switch Coil for Hansen solenoid valve TO ORDER SPARE PARTS PLEASE CONTACT YOUR DISTRIBUTOR IOTA Service Manual 11 7 TABLES amp CHARTS TEMPERATURE PRESSURE CHART FOR COMMON REFRIGERANTS DegF R 12 R 22 DegF R 12 R 22 R 502 R 134a MP 39 R 404a 80 502 134 39 404 80 7 6 0 2 9 0 91 00 1 2 50 46 7 84 0 974 102 9 111 4 7 2 0 7 8 7 08 2 1 52 48 8 87 3 101 0 47 7 60 0 109 0 120 0 6 8 17 15 83 83 16 2 9 54 51 0 90 8 104 8 113 0 124 0 2 3 79 25 3 9 56 532 943 108 6 117 0 129 0 3 2 7 4 3 4 4 9 58 554 979 1124 121 0 133 0 60 577 101 6 116 4 125 0 138 0 EA 120 4 130 0 142 0 625 1093 124 6 134 0 147 0 192 128 8 65 5 79 0 139 0 152 0 68 67 6 117 3 133 2 68 3 82 0 144 0 157 0 A MESE I x 0 4 N alo Nu 02 co 92 48 137 6 148 0 162 0 10 3 Lm 729 1257 142 2 153 0 168 0 11 5 74 755 190 0 146 8 158 0 173 0 o E gt wjo
56. TION ACCUMULATOR 88 FLOAT SWITCH 22 LIQUID FEED SOLENOID VALVE VALVE 20 HAND EXPANSION VALVE 17 FREEZER REFRIGERANT CHARGING VALVE 28 LIQUID FEED SOLENOID VALVE 2 VALVE 21 FILTER DRIER 46 1 6 INTRODUCTION 8 1 07 SAFETY RELIEF VALVE 50 RECEIVER 15R RECEIVER SIGHT GLASS 30 THAWING GAS SOLENOID VALVE D VALVE 18 RECEIVER DRAIN VALVE 44 GEAR REDUCER 5R MAKE UP WATER FLOAT VALVE 12 FIGURE 1 3 Assembly Air Cooled Left Side View 10 Service Manual COLD WEATHER SOLENOID VALVE X VALVE 53 OIL SEPARATOR 14 CUTTER MOTOR 5M 1 2 MPT MAKE UP WATER CONNECTION 8 1 07 10 Service Manual CONDENSER pz 15 K THAWING GAS 1 STOP VALVE 90 CONTROL PANEL Re S 1 t COMPRESSOR 3 LIQUID OUTLET STOP VALVE KING VALVE 58 WATER TANK 7 FIGURE 1 4 Assembly Water Cooled Front View 1 7 INTRODUCTION HEAT EXCHANGER 13 LOW PRESSURE GAGE 1PG HIGH PRESSURE GAGE QPG OIL PRESSURE SWITCH 94 HIGH LOW PRESSURE SWITCH 4PS HIGH PRESSURE TEST CONNECTION LOW PRESSURE TEST CONNECTION CIRCULATING WATER PUMP 6 1 8 INTRODUCTION SAFETY RELIEF VALVE GD LIQUID RETURN STOP VALVE 91 OIL RETURN STOP VALVE 70 1 FPT WATER TANK DRAIN 8 1 07 H H H FIGURE
57. art Up Form Medium amp Large Machines Model Number Serial Number This form must be filled out completely and signed by the customer in order to assure acceptance by Vogt Date of Start Up Form Completed By AC Condenser Model Number AC Condenser Serial Number Water Treatment System Yes No Manufacturer Model Bin Manufacturer Model Bin Capacity lbs Distributor Company Name Phone Address City State Zip Service Company Company Name Phone Address City State Zip Customer location of equipment Company Name Phone Address City State Zip PRE OPERATION CHECK OPERATION CHECK Machine room suitable 50 minimum 110 maximum L Power Supply HZ machine running Power Supply V PH HZ machine not running Compressor oil level i e 1 4 1 2 3 4 Crankcase heater on for 2 hours minimum prior to start L Compressor pump cutter amp other motor direction of rotation correct All valves opened or closed as tagged L Compressor amps Start of freeze cycle L1 L2 L3 Water supply and drains connected properly Cutter motor amps Actual L Sufficient make up water supply minimum 30 PSIG TT Water pump amps RLA Actual Leak checked entire system including AC condenser if applicable Condenser motor amps if applicable L AC condenser cold weather temp
58. butors The water distributors are located under the freezer cover at the top of the freezer These distributors may require occasional or periodic cleaning to remove solids and foreign particles accumulated from the make up water The frequency of this cleaning operation will depend on the characteristics of the water supply The cleaning operation is needed when the inside diameter of a large proportion of the ice becomes irregular due to channeling of water or if some of the ice is opaque or if there is a noticeable decrease in ice capacity Vogt Part Size Ice Number of Tubes Water Distributor Freezer Cover Freezer Cover Gasket 1 156 12B2185N11 1BA2145C03 12A2600G15 1 1 4 102 12B2185N21 1 1 2 72 12B2185N31 TABLE 7 1 Number of Water Distributors Per Tube Size To clean distributors stop the unit and remove the freezer cover on top of the freezer The water distributors one in each tube may then be removed with pliers for cleaning Use pliers on the distributor s top part with a twisting upward motion Use care when removing distributors to avoid distorting orifice holes or the body of the distributor The distributors can be soaked in ice machine cleaner to remove mineral buildup Rinse distributors thoroughly before reinstalling and tap lightly with a rubber mallet to seat them in the freezer tubes 11 4 11 2 Hole Size 1 16 1 8 1 8 3 16 1 4 3 8 Avg Avg Avg
59. c system shutdown and restart based on current line conditions a voltmeter and a non volatile system memory so settings are retained even if power is lost If machine is ordered with this option the power monitor can be factory set to customer specifications The Vogt Part number for a power monitor retrofit kit is 12A7700K01 D EAC 8002 LINEBACKER PHASE PROTECTOR Y LINE Si SS SETUPY 5 Y a ENERGIZED CONTROL ES LOAD CONTROL EC com NC ALARM 9 NO RUN LINE 1 LINE 2 LINE 3 e el e FIGURE 10 1 Power Monitor Linebacker Phase Protector Operation Modes LINE Mode To enter this mode press the LINE key Allows the reading of phase to phase and average voltages of the line inputs Also in this mode the Delay on Break and Delay on Make timers are displayed If the EAC 8002 is left in any mode other than CLOCK after 3 minutes of the keyboard inactivity it will switch automatically to LINE mode LOAD Mode To enter this mode press the LOAD key Allows the reading of phase to phase and average voltages of the contactor load inputs Also in this mode the Delay on Break and Delay on Make timers are displayed CLOCK Mode To enter this mode press the CLOCK key once The display will show the current date and time You will be
60. cations CAUTION Cutter and pump motor rotation are factory synchronized but must be checked at installation For ice production the cutter disc as viewed at the ice discharge opening should turn from left to right crushed rotation should be from right to left The pump rotation should match the marking on the pump housing The pump will need to be primed by starting the machine in the clean mode and allowing it to run for several minutes To change direction of rotation for both cutter and pump disconnect power and reverse L1 and L3 incoming power wires at the compressor motor contactor Voltage Unbalance Voltage unbalance can cause motors to overheat and fail The maximum voltage unbalance between any two legs should be no greater than 2 Example Supply Voltage 230 3 60 Voltage Readings AB 220 Volts 225 Volts Average 220 225 227 3 224 Volts 227 Volts AB 224 220 4 Volts Highest Deviation 225 224 1 Volts Voltage Unbalance 100 x 4 224 1 78 Acceptable AC 227 224 3 Volts Important If the supply voltage phase unbalance is more the 2 contact your local electric utility company Current Unbalance Voltage unbalance will cause a current unbalance but a current unbalance does not necessarily mean that a voltage unbalance exists A loose terminal connection or a buildup of dirt or carbon on one set of contacts would cause a higher resistance on that leg
61. ce reading higher than 10 000 ohms On initial start up and after any module trip due to high temperatures the resistance of the sensors must be below the module reset point before the module circuit will close Reset values are 2700 4500 ohms If the sensors have the proper resistance and are below 2700 ohms resistance the compressor will run with the control circuit bypassed but will not run when connected properly the solid state module is defective and must be replaced The replacement module must be the same voltage and be compatible with the original module on the compressor 9 8 10TA Service Manual SERVICE OPERATIONS Compressor Terminal Board Black Common Electronic Motor Protector Module T2 T1M2 1 Part No 12A2110P0917 4D amp 6D compressor 1 31 3 4D 6D 8D 4R 6R Electrical Installation Diagram for the Electronic Module FIGURE 9 6 Electronic Module and Compressor Terminal Board Connections Copeland Compressor Sentronic Oil Pressure Safety Control The Sentronic utilizes a pressure sensor and an electronic control module to precisely measure oil pump differential pressure The main advantage of 8 21 06 8 21 06 10 Service Manual 9 9 SERVICE OPERATIONS Sentronic is the elimination of the traditional capillary tubes bellows and pressure connections that mechanical pressure switches require to measure differential oil pressure These require careful handling
62. cute this command press the FAULT key again You will be asked to confirm the command Use the UP amp DOWN keys to make your selection and press the FAULT key to execute If you are using password you will also be asked to enter it Note Erasing the registers does not perform a Manual Reset as well as a Manual Reset does not erase the fault registers SETUP Mode Press the SETUP key to enter the SETUP mode Use the UP amp DOWN keys to navigate through the parameters To change settings press the SETUP key while the display is showing the parameter you want to change The display cursor will start blinking Use the UP amp DOWN keys to increase or decrease the parameter value or to choose among the available options Press the SETUP key again to save the new parameter value Parameter limits Parameter Minimum Maximum Default Unit Nominal Voltage 190 600 208 Volts Over Voltage 2 25 10 Under Voltage 2 25 10 Phase Unbalance 2 20 5 Delay Break 0 1 25 0 5 Minutes Delay on Make 0 1 10 0 1 Minutes Delay on Fault 1 15 2 Seconds Contactor Test OFF 10 OFF Retries Contactor Fault 10 50 25 Parameter Options Default Reset Mode Manual Auto Manual Control Mode Off On External External Language English Spanish French Portuguese English Restore Defaults No Yes No Using Password No Yes No TABLE 10 1 Power Monitor Parameters 8 1 07 10
63. cycle The function of the capillary bypass is to meter a set minimum amount of refrigerant to the freezer during the freeze cycle thereby reducing cycling of the float switch High Low Pressure Switch Part No 12A2117D02 The high low pressure switch HPS FIGURE 9 4 is a two pole dual function switch Located in the machine mounted to the frame near the compressor It protects the machine from possible damage due to abnormal pressure during operation CAUTION When this switch causes the machine to stop the cause should be identified and corrected before resuming normal operation CAUTION The LOW pressure cut in should be set at 40 psig and the cutout set at 20 psig for R 22 The LOW pressure cut in should be set at 52 psig and the cutout set at 28 psig for R 404a NOTE After tripping at the cutout setting the switch will reset automatically when the pressure rises to the cut in setting The HIGH pressure cutout should be set at 300 psig for R 22 and 350 psig for R 404a After tripping reset the switch manually RANGE ADJUSTING SCREW SET AT 40 PSIG R 22 SET AT 52 PSIG R 404A CW RAISES SETTING DIFFERENTIAL ADJUSTING SCREW SET AT 20 PSIG CW RAISES SETTING RESET BUTTON HIGH PRESSURE ADJUSTMENT SET AT 300 PSIG R 22 SET AT 350 PSIG R 404A CW RAISES SETTING LOW PRESSURE DIFFERENTIAL FACTORY SET TEST CONNECTION kel HIGH PRESSURE TEST CONNECTION FIGURE 9 4 High Low Press
64. d on the shaft so it will have a full vertical mesh with the cutter ring gear Final gear meshing should be adjusted so there is only a slight amount of play between the ring gear and drive Make sure all bolts are tightened securely and there is no excessive gear noise when the cutter motor is running Water Tank Removal 9 18 SERVICE OPERATIONS 8 21 06 ces 10TA Service Manual Turn off and lock out power to the machine Turn off water supply and disconnect lines from the tank Drain the tank and disconnect pump suction tube and drain line tubing and water lines Disconnect the ice discharge chute Loosen bolts holding the tank to the cutter assembly until the tank rests on the bars Loosen bolts holding the tank supports The tank can then be removed to the side of the machine Make sure the rubber gasket is in place and aligned properly when the tank is installed and bolted to the freezer Cutter and Bearing Removal Installation Refer to FIGURES 9 14 amp 9 15 for parts identification and location aod E Turn off and lock out power to the machine Remove the cutter motor from the reducer Remove the water tank assembly and then the cutter assembly With a 1 4 or slightly smaller punch reach in through the ice discharge opening drive the spiral pin out of the disc hub and cutter shaft and push or drive the disc off the shaft Lift the cutter assembly out of the bearing surface of the cutter The su
65. day Consult Specifications for Actual Capacity 3 tons day OST 5 tons day 10 tons day 25T 25 tons day 50T 50 tons day 80T 80 tons day Basic Configuration P Package L Low side H High side Tube Size in 1 A s of an inch 5 1 1 4 6 1 2 gn 2 Model Variation A number assigned to indicate major variations within any one family series Refrigerant F R 22 A Ammonia H R 404a Electrical Codes 26 208 230 3 60 46 460 3 60 56 575 3 60 25 200 3 50 45 400 3 50 21 230 1 60 XXXX XXXX XXXX XXX Type of Ice Cylinder K Crushed D Dual Ice Cru amp Cyl L 1 1 2 Long Cylinder X 2 Long Cylinder Condenser Type AC Air Cooled WC Water Cooled HP High Pressure Water Cooled SW Sea Water NC No Condenser Product Variation Codes An alphanumeric designator assigned to specific variations 000 or Blank Standard Product If unsure of the product code shown on your machine please consult the factory Figure 2 1 Vogt Model Nomenclature 6 15 05 10 Service Manual 3 1 INSTALLING YOUR TUBE ICE MACHINE 3 Installing Your Tube Ice Machine Only service personnel experienced and certified in refrigeration and qualified to work with high voltage electrical equipment should be allowed to install or work on this Tube Ice mach
66. ded Please heed DANGER Indicates an immediate hazard and that special precautions are necessary to avoid severe personal injury or death DANGER WARNING Indicates a strong possibility of a hazard and that an unsafe practice could result in severe personal injury WARNING CAUTION Means hazards or unsafe practices could result in personal injury or product or property damage CAUTION 8 1 07 1 4 INTRODUCTION THAWING GAS STOP VALVE 90 CONTROL PANEL 1 FAN CONTROL SWITCH 41A COMPRESSOR 3 LIQUID OUTLET STOP VALVE KING VALVE 58 WATER TANK 7 8 1 07 10TA Service Manual _ HEAT EXCHANGER o 2 gt 13 LOW PRESSURE De AL GAGE 1PG 62086 HIGH PRESSURE HH GAGE 2PG OIL PRESSURE SWITCH 94 HIGH LOW PRESSURE SWITCH 4PS HIGH PRESSURE TEST CONNECTION LOW PRESSURE TEST CONNECTION CIRCULATING WATER PUMP 6 FIGURE 1 1 Assembly Air Cooled Front View 10 Service Manual SAFETY RELIEF VALVE 51 CHECK VALVE 101 CONDENSER SERVICE CONNECTION 32 LIQUID RETURN STOP VALVE 91 OIL RETURN STOP VALVE 70 1 WATER TANK DRAIN 8 1 07 ll e a I FIGURE 1 2 Assembly Air Cooled Right Side View 1 5 INTRODUCTION FREEZER 2 FREEZER PRESSURE STOP VALVE 69 SUC
67. down period If the level is low after start up it should begin to return after a short period of operation The oil level should be checked frequently particularly during the start up operation to see that a sufficient amount of oil remains in the crankcase While it is important to observe the oil splash during operation the true level can be obtained only when the compressor is stopped With the compressor idle the oil level should be at a height of 1 4 to 1 2 of the sight glass but never out of sight above it The machine is properly charged with oil for the test operation but it may be necessary to add some oil when or if new refrigerant is added to the system Generally air cooled machines will require additional refrigerant and oil to compensate for long piping runs to the condenser Refrigerant Recommended Lubricants Type of Lubricant HCFC 22 R 22 Suniso 3GS Texaco WF32 Calumet RO15 Witco Mineral Oil R 404A Mobil EAL ARCTIC 22 CC ICI Virginia KMP Emkarate Polyol Ester Oil RL 32S TABLE 7 3 Recommended Lubricants Compressor HP Oil Charge oz 6DY3 3000 TSK 30 140 6DN3 3500 TSN 35 140 TABLE 7 4 Compressor Oil Capacity 8 1 07 10 Service Manual 7 7 MAINTENANCE An oil pump should be used to force any oil that may be required into the system Oil may be added to the compressor through the oil separator oil return line fitting on the compressor or the compressor
68. e located inside a suitable building and must not be subjected to ambient temperatures below 50 F 10 C or above 110 F 43 3 C Heat from other sources sunlight furnaces condenser etc and unusual air current may affect the operation of the machine and should be avoided The electrical components of the Tube Ice machine are rated NEMA 1 Therefore the machine should not be located in a hazardous area or sprayed with water The machine should be installed on a drainable condensate drip pan or in an area where water will not stand but will readily drain away from the machine See Space Diagram for clearances and utility connections FIGURES 3 24 and 3 2B 2 2 RECEIPT OF YOUR TUBE ICE MACHINE 8 1 07 10TA Service Manual Storage prior to installation or start up The machine must not be stored or installed in an area that may reach temperatures 115 F 46 1 C or above CAUTION This equipment contains HCFC 22 refrigerant under pressure Do not store in an area exposed to temperatures above 115 F 46 C or in direct sun at temperatures above 105 F 40 C CAUTION The machine nameplate is located on the front of the control panel The model number and machine description are located in the top left hand corner The following figure can be used to verify that the correct model has been received Nominal Capacity 02K 2000 Ibs day K 1000 s Ibs day T tons day 03K 3000 Ibs day 04K 4000lbs
69. ed the warranty on the module is voided No attempt should be made to adjust or repair this module and if it becomes defective it must be returned intact for replacement Electronic Motor Protector High Potential Testing The solid state sensors and the electronic components in the solid state module are delicate and can be damaged by exposure to high voltage Under no circumstances should a high potential test be made at the sensor terminals with the sensor leads connected to the solid state module Even though the power and pilot circuit leads are not connected the module can be damaged 8 21 06 10 Service Manual 8 21 06 9 7 SERVICE OPERATIONS Electronic Motor Protector Field Trouble Shooting In the event the motor compressor is inoperable or is not operating properly the solid state control circuit may be checked as follows If the compressor has been operating and tripped on the protector allow the compressor to cool for at least one hour before checking This allows time for the motor to cool and the control circuit to reset WARNING Before checking the TI31AA model for its attached wiring sensor be aware that the sensor terminal has the same voltage as terminal L1 WARNING Disconnect control circuit power to deenergize the module Connect a jumper wire across the control circuit M1 M2 terminals on the module control circuit terminal board This will bypass the control contact of the mod
70. eded fans reduces on off cycling of the fan s and allows for a steadier condensing pressure and more consistent warm gas for ice harvesting 3 8 6 15 05 10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE 14 When extreme cold conditions are expected or encountered temperatures below and wind 15 16 7 18 greater than 15 it may be necessary to install a protective enclosure around the condenser Apparatuses such as louvers may also be used for varying conditions Contact the factory for suggestions After installation the field installed lines are to be evacuated to a vacuum of 500 microns or less and held for at least one hour After the vacuum pump is removed vacuum should hold at 500 microns or less for at least 5 minutes The machine is shipped with a full operating charge of refrigerant sufficient to fill the condenser and connecting lines If the condenser piping is longer than 50 feet one way additional R 22 or R 404A may need to be added to retain enough refrigerant in the receiver for thawing purposes see table Refer to the operating level mark on the receiver and charge accordingly Each 1 of liquid level in the receiver equals approximately 5 5 pounds of R 22 or R 404a Liquid Line Size 75 ft 100 ft 125 ft 150 ft 6 wr 4 A A LU8 6 102 18 TABLE 3 3 Pounds of R 22 to Add vs Liquid Line Length piping must be done in accordance
71. efrigerant R 22 or R 404a depending on the model which has been isolated in the receiver 15R Before shipment of the machine the compressor service valves 34 35 and the stop valves in the various lines to the condenser and receiver have been closed These valves are tagged with instructions that the valves are to be opened prior to start up of the machine Before opening these valves it is advisable to check all joints for leaks that may have developed during shipment If no leaks are present a positive pressure should show on the suction and discharge pressure gages They should indicate a pressure approximately equal to the ambient temperature This pressure can be found using the pressure temperature chart for the applicable refrigerant TABLE 11 7 If it should ever become necessary to add refrigerant to the system charging valve 28 is provided for this purpose Through this valve refrigerant can be added in liquid form See Adding Refrigerant The compressor crankcase heater must be energized for a minimum of two hours prior to starting and running the compressor 5 2 10TA Service Manual START UP AND OPERATION Start Up CAUTION The crankcase heater should be energized for a MINIMUM of 2 hours and the crankcase must be free of liquid before attempting to operate the compressor CAUTION Off Clean Ice Start Manual Harvest Stop 7 7 7 rd Ga DN N CONTROL PANEL DOOR FIGURE 5 1
72. engineering and fabrication that we have learned in over a century of experience is reflected in the 10TA model Tube Ice machines Since Vogt introduced Tube Ice machines in 1938 the process of making Tube Ice ice has been widely recognized as the most economical means of production The machine s economic and reliable operations have been proven over and over again in a network of varied types of installations throughout the world Furnished with your machine is the Certificate of Test the report of operating data that is a record of the unit s satisfactory operation on our factory test floor It is evidence of our desire to deliver to you the finest ice making unit ever made This manual is designed to assist you in the installation start up and maintenance of your unit Your Tube Ice machine will give you a lifetime of service when you install it maintain it and service it properly Please read your manual carefully before attempting installation operation or servicing of this professionally designed piece of equipment If you have additional questions please call your distributor Also feel free to phone the factory direct at 502 635 3000 or 1 800 853 8648 1 1 1 2 10TA Service Manual INTRODUCTION Important Safety Notice This information is intended for use by individuals possessing adequate backgrounds of electrical refrigeration and mechanical experience Any attempt to repair major equipment may result in pers
73. erature setting s Incoming potable water temperature Solenoid Fan L All water distributors in place visually inspected AC condenser installed above machine Yes No Make up water float valve adjusted properly Approx ft Clearice Yes No L AC condenser line length in equivalent feet Bin control s operate s properly to stop and start machine with ice L AC condenser properly piped all lines insulated on them Bin control s installed properly Hour meter in control panel connected and operating Instruction manual and warranty certificate left on site Suction Pressure End of freeze End of harvest Name of person left with Discharge Pressure End of freeze Endofharvest Test Make up Water Freeze Time Harvest Time First Ice Out All Ice Out Avg Hole Ice Temp Min Sec Min Sec Min Sec Min Sec Size Lb Per Harvest Lb Pi ET Ice Ib per day can be found by ice Ib per harvest freeze time harvest time Remarks Technician Signature End User Signature I certify that I have performed all of the above procedures 12 16 04 222 oi 595262 SC SORELY SC D Meads gt TUBE ICE LLC located in Louisville Kentucky since 1880 Sales 800 959 8648 Service 502 635 3000 Parts Your Local Distributor Call your local distributor first for all of your parts and se
74. flow down the drain With petcock valve open allow water to circulate for a minimum of 3 minutes Press Stop button to stop pump then drain and flush water tank with fresh water Open water supply to machine To sanitize inside the ice storage area flood the area with sanitizing solution making sure to wet all surfaces completely for at least 60 seconds Note Concentration should be 200 ppm active sanitizing solution Nu Calgon IMS II 1 6 ounces of sanitizer per 1 gallon of water 200 ppm Drain flush tank and refill with fresh water Return machine to ice making operation 1 2 3 5 Make sure the water tank drain valve is closed and the Selector switch is in the Off position Turn on the water supply and refill tank with clean water Manually open the thaw gas solenoid valve D valve 18 by running the stem in This will allow the pressure to rise in the evaporator and allow the machine to operate After approximately 1 minute put D valve back into the automatic position When tank is full turn the selector button to the Ice position and push the Start button for immediate start up in the ice production mode Make use the adjustable blow down petcock is adjusted properly NOTE The petcock should be adjusted to the minimum rate required to maintain production of clear ice Should be no more than 1 gallon 5 minutes 8 1 07 10 Service Manual 7 3 MAINTENANCE Water Distri
75. from the freezer raises the tank level and causes an overflow of water which creates a siphon to remove a fixed amount of water from the tank Make up Water Float Valve Part No 12A4200H0402 The make up float valve 12 maintains the proper pumping level in the water tank for ice making The valve should be set to maintain a water level in the water tank during the freezing period so that there will be a quantity of by pass or blowdown only during the thaw mode The water level during the freeze mode should always be below the by pass piping to prevent excessive waste of cold water resulting in loss of ice capacity If it should become necessary to clean the float valve close the stop valve in the make up water line to the machine and remove the float valve After the valve has been cleaned and reinstalled check to ascertain if the proper water level is being maintained After the machine is stopped and the water in the tank seeks its normal level there should be no water flow through the float valve or drain by pass It is advisable to install a large area strainer in the water supply line to protect the float valve from dirt or solids in the water which would necessitate frequent cleaning A strainer of 40 mesh screen is usually satisfactory 9 2 10TA Service Manual SERVICE OPERATIONS Float Switch Part No 12A7500E22 The float switch is installed on a header assembly that is attached to the freezer shell Valves are provided for isola
76. g the thaw period at the set point Pump Motor Starter Manual motor starter and contactor Starts and stops pump motor Provides short circuit and over current protection Stops water pump motor in the event of a mechanical or electrical malfunction that results in excessive motor amperes PB1 Used to stop machine immediately Should be used for emergency stopping only PB2 Used for starting machine or manually harvesting Will initiate a harvest cycle whenever pushed with the Clean Off Ice selector switch in the Ice position and machine operating in a freeze cycle PF Stops the machine when there is a power failure or interruption Also stops the machine when the high low pressure switch oil pressure safety control pump overload cutter overload compressor overload or the control circuit breaker is tripped If the Stop button was pushed any of the safeties tripped or there was a power outage the machine must be manually restarted by pushing the Start button SS Used to select operating mode of machine When in clean position only the water pump will run This allows cleaner to be circulated through the freezer without making ice In the off position the machine will shut down after the completion of a freeze and harvest period In the ice position machine will cycle on and off based on a control signal i e bin thermostat or timer or run continuously until manually stopped by setting the switch
77. he numbers you see in parentheses refer to the numbers in this piping schematic The freezer 2 is a shell and tube type vessel During the freezing period water is constantly recirculated through the vertical tubes of the freezer by a centrifugal pump 6 Make up water is maintained by a float valve 12 in the water tank 7 Solenoid valve 20 sometimes referred to as A valve is open and solenoid valve 18 sometimes referred to as the D valve is closed Refrigerant gas from the top of the freezer 2 passes through the suction accumulator 88 the heat exchanger 13 and to the compressor 3 Here the cool gas is compressed to a high temperature high pressure gas which discharges through the oil separator 14 and into the condenser 15 In the condenser heat is removed and the gas is condensed to a high temperature high pressure liquid The high pressure liquid goes through the accumulator boil out coil 88 and suction line heat exchanger 13 where it is gives up heat to the suction gas for compressor protection In addition this liquid is subcooled and carried to the receiver 15R Condensed liquid refrigerant from the receiver flows through the thawing chamber 16 of the freezer the filter drier 46 the A1 and 2 liquid feed valves 20 amp 21 and then the expansion valve 17 and capillary 19 At the expansion valve 17 and capillary bypass 19 the refrigerant is taken from a saturated liq
78. heck for leaks Mechanical cleaning Part I a Close the stop valve in the water supply line b Drain the water from the condenser c Remove water regulating valve 41 and attached piping to the condenser d Remove the cover plate on the side of the frame to expose the condenser end plate e Remove the nuts water plates and gaskets from both ends of the condenser If the gasket does not lift off with the end plate do not try to pry it off The seal surface may be damaged which would cause a water leak To free a sticking gasket replace the water plate and tap it on the outside face with a mallet or a block of wood After a few taps the gasket will spring free and will then slip off with the water end plate f Gaskets need only be rinsed in running water rust scale or dirt will not stick to gasket material A rag or soft brush is all that is required to remove any foreign matter Part II The inside of the water end plates and the outer tube sheet surfaces should be cleaned only with clear water and a rag or a soft bristle brush A worn paint brush is excellent These surfaces have been coated with a special material which will give years of protection against corrosion unless damaged Never use a wire brush or a strong caustic on these surfaces Flush condenser tubes clear with air water or a piece of rag on a stick or wire In many cases this is all that is required If the inside surfaces are smooth even though discolored
79. heck the normally open solenoid valve to make sure it is open also check the fan sequencing thermostats and fan motor contactors to make sure they are functioning properly Replace any defective parts Dirty condenser causing restricted air flow Visually inspect condenser and clean as necessary Non condensables usually air in the system Follow same procedure as specified for removing non condensables from Water Cooled machine except evacuate the air cooled condenser also 8 1 07 8 21 06 10 Service Manual 9 1 SERVICE OPERATIONS 9 Service Operations Adjustable Blowdown for clearer ice A petcock is installed on the overflow of the water pump to provide means for obtaining blowdown from the water tank during the freezing period The petcock was set at the factory to discharge enough water during the freeze cycle to produce clear ice After installation it should be adjusted to the minimum rate required to maintain clear ice and checked after a few days of ice making Adjustable Blowdown petcock valve Automatic Ss Blowdown Water Pump 3 FIGURE 9 1 Water Pump Blowdown Assembly Automatic Blowdown Harvest Cycle A feature of this machine is the automatic blowdown 40 which is provided to eliminate or reduce the necessity for frequent flushing or cleaning of the water tank 7 and to remove accumulated salts or solids in the water as a result of the freezing action During the harvest water returning
80. hine is proportional to ice making water temperature Warmer water will reduce the ice making capacity See Section 11 Capacity Table Drain valve 12 open Close drain valve 12 SYMPTOM Low compressor oil level POSSIBLE CAUSE POSSIBLE REMEDY Oil separator not returning oil Check oil separator float and oil return stop valve 70 and line for a restriction The oil return line should be above ambient temperature most of the time as it returns oil It may be cooler at the start of a freeze cycle Repair or replace defective parts Repeated short cycling refrigerant carrying oil out of Usually caused by freeze up low refrigerant charge low head compressor pressure faulty timer faulty pressure switch or expansion valve clogged Use process of elimination Worn piston rings This condition is hard to detect without dismantling the compressor and checking piston ring tolerances Normally there will be a little puddle of oil laying on top of the piston when the head and valve plate are removed It is best to replace the compressor 8 1 07 10 Service Manual 8 5 TROUBLESHOOTING SYMPTOM High head pressure Water cooled machine POSSIBLE CAUSE POSSIBLE REMEDY Misadjusted or defective water regulating valve Adjust or replace the valve Never adjust the valve stem as far open as it will turn because it will not close when the head pressure drops Insufficient water supply Check size of water line and pum
81. ical Frequency 640 50020 Fans Number 5 5 1 2 1 2 Total 33 000 32 500 Full Load Amps FLA 3 ph 208 230V 60 hz 3 ph 460V 60 hz 3 ph 200V 50 hz 3 ph 380V 50 hz Locked Rotor Amps LRA 3 ph 208 230V 60 hz 3 ph 460V 60 hz 3 ph 200V 50 hz 3 ph 380V 50 hz Weight lbs Net Shipping Operating Maximum flooded R 404a Condenser Dimensions inches See Fig 3 7 A Width 57 57 Length 180 1 8 180 1 8 C Height 45 5 8 45 5 8 D Leg centerline 55 1 4 55 1 4 E Leg centerline 147 5 8 147 5 8 F Clearance below 14 5 8 14 5 8 Recommended Line Sizes OD Liquid All lengths and orientations 3 8 1 1 8 Discharge Gas Vertical Up all lengths 1 8 1 1 8 Horiz or Down 75 ft 1 1 8 1 1 8 Horiz or Down 75 ft 3 8 3 8 Connections Condenser Liquid ODF 3 8 1 3 8 Discharge Gas ODP 2 1 8 2 1 8 Connections Ice Machine Liquid ODF 1 1 8 1 1 8 Discharge Gas ODF 1 3 8 1 3 8 TABLE 3 4 Air Cooled Condenser Data 3 10 10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE ELECTRICAL CONNECTION BOX THIS END As DIA MOUNTING HOLES E MOUNTING HOLE CENTERS MOUNTING HOLE CENTERS FIGURE 3 4 Condenser Dimensions Condenser pictured DD 231 SOLENOID VALVE SAFETY VALVE MINIMUM DROP TO MACHINE Note Dash lines indicate customer supplied piping
82. ine WARNING Important Notice The Warranty Registration Start Up Form must be completed and returned to Vogt Tube Ice to initiate and assure a full warranty A postage paid envelope is provided or you may fax the report to 800 770 8648 Piping and Drain Connections Figure 3 2A Air Cooled and 3 2B Water Cooled show locations and sizes for all connections CAUTION External shut off valves must be provided in the water inlet lines The minimum inlet water pressure for satisfactory operation of the machine is 30 psig The maximum allowable pressure is 100 psig CAUTION Make up Water Tank Condenser Condenser Water In Drain Water In Water Out 1 2 1 2 FPT 2 1 2 FPT TABLE 3 1 Water Supply and Drain Sizes condenser water outlet and water tank drain connections must be extended to an open drain or sump arranged for visible discharge Do not trap the water tank drain line as this will interfere with the operation of the automatic blowdown system CAUTION These lines must NOT be connected into a pressure tight common header due to the possibility that warm condenser water may back up into the water tank The condenser water outlet MUST be piped separately to the drain CAUTION Note Due to variations in water quality by geographic location water filtering or treatment may be required to reduce maintenance and inhibit hardness buildup on machine components
83. ion especially as the suction pressure decreases Float switch stuck or failed in open position Make sure the float switch is opening and closing Make sure the 1 valve is getting power Thawing gas solenoid valve 18 leaking through during the Check the manual opening stem to make sure it is in the freeze cycle automatic position stem screwed out Check for leakage through the valve by sound and temperature difference Close the stop valve 90 at the receiver to confirm suspicion of leakage Repair or replace the valve as needed Water distributors at top of freezer may be stopped up Remove freezer cover and clean the distributors See Water Distributors Section 7 Inadequate water for ice making Check water pressure 30 PSIG minimum recommended Check for a water restriction in the supply line or at the make up water float valve or water tank drain valve 15 open or leaking replace water tank drain valve Controls for regulating freezing and thawing cycles not For highest capacity cylinder ice should have a small hole adjusted properly and crushed ice should be about 3 16 thick Check the freezer pressure switch and thaw timer for proper adjustment Section 9 Excessively high head pressure Check water regulating valve or fan control adjustment Check to make sure the WC or AC condenser is clean Check refrigerant tables for pressure temperature relation Warm make up water for ice making Capacity of the mac
84. isconnect to stop the machine If the disconnect is used the crankcase heater will be de energized and liquid refrigerant will migrate to the compressor If in a freeze mode the machine will continue to run At the completion of the freeze cycle the machine will harvest and stop The completion of a cycle ensures that all ice is removed from the freezer to prevent refreeze when the machine is restarted If in a harvest the machine will complete the harvest and stop Operating Tips If the operation of your machine is not controlled by a timer bin level control or some other mechanism to automatically start and stop ice production you should use ONLY the Clean Off Ice toggle switch to start and stop machine By turning the Clean Off Ice selector switch to Off the machine will stop after the next harvest cycle Do not use the Stop push button or the machine disconnect for normal shutdown of the machine Throw the Disconnect only in an emergency or for safety when performing certain service or repairs to the machine The compressor crankcase heater is de energized when the disconnect is thrown The Start push button can be used to initiate a harvest cycle When it is pushed during a freeze cycle it will immediately initiate a harvest cycle 5 4 10TA Service Manual START UP AND OPERATION Adding Refrigerant CAUTION If it should become necessary to add refrigerant to the system
85. jN EE N 151 5 164 0 179 0 EAEN 156 3 635 992 169 0 184 0 84 2 143 6 161 2 174 0 190 0 87 2 148 4 166 2 90 2 180 0 196 0 902 153 2 171 4 185 0 202 0 93 3 158 2 176 6 191 0 208 0 96 5 1632 181 9 197 0 214 0 998 1684 187 4 203 0 220 0 103 1 106 5 110 0 184 6 oO Ni Gr BR OPN SSL S Sole a a a a o o Au 192 9 209 9 227 0 198 6 215 0 234 0 184 6 204 3 222 0 240 0 210 2 138 0 229 0 247 0 1172 216 2 142 0 235 0 254 0 222 3 242 0 261 0 aor 228 5 249 0 269 0 234 9 256 0 276 0 132 4 220 0 241 3 264 0 284 0 136 4 226 4 247 9 271 0 292 0 140 5 232 8 254 6 279 0 299 0 144 7 239 4 261 5 286 0 307 0 268 4 294 0 316 0 153 2 252 9 275 5 302 0 324 0 SR 80 82 84 86 __ 88 90 92 94 96 98 100 102 1 104 106 1 108 110 112 114 116 118 _ 120 28 148 3 e 43 0 1 5 18 4 259 9 282 7 171 3 191 0 311 0 332 0 22 4 54 9 122 16 290 1 319 0 341 0 23 9 57 5 124 16 297 6 328 0 350 0 25 4 60 1 126 17 305 2 336 0 359 0 26 9 62 8 128 17 312 9 345 0 368 0 28 5 549 65 6 130 18 320 8 354 0 377 0 30 1 68 4 27 8 oe 328 9 204 7 225 0 364 0 387 0 31 7 60 1 71 3 29 5 312 5 337 1 210 7 231 0 37
86. k to the ice machine with no traps in the liquid line Horizontal runs in the discharge line should slope 1 4 per foot in the normal direction of flow away from the ice machine Traps must be installed in discharge lines at the base of all vertical risers There should be no intentional traps in liquid lines Trap volume should be kept to a minimum Long vertical rises should have traps every 20 feet Typical details are shown in FIGURE 3 6 Flooding head pressure controls such as Alco Headmaster are not to be used since they cause excessive subcooling of the returned liquid refrigerant and interfere with reliable ice harvest The discharge and liquid lines must be insulated with 1 2 thick Armaflex insulation or equal Use only ACR grade copper pipe Type L Recommended line sizes are shown in TABLE 3 3 For field attachment instructions see FIGURE 3 4A Distance between ice machine and condenser must not exceed 150 equivalent feet Refer to Condenser Equivalent Line Size worksheet see TABLE 3 5 Condensers must be provided with a cold weather valve kit per FIGURE 3 5 These valves allow one half of the condenser to be disabled in cold weather Running the ice machine with one half of the condenser in cold weather makes it easier to maintain minimum necessary condensing pressure particularly in windy conditions Condensers with multiple fans must be provided with a thermostat to turn off unneeded fans in cold weather Turning off unne
87. k top flange there should be 0 to 1 16 clearance between the rim of the cutter and the top of the tank flange Loosen the bearing support cap screws and drive the support arms up or down for the proper alignment Tighten the support screws securely and finish assembly of the cutter and cutter disc Install the tank and other parts reversing the procedure of removal 10 Service Manual 9 19 SERVICE OPERATIONS FREEZER CUTTER BEARING 47 BEARING GASKET SUPPORT BRACKET 1 gees e 7C a 8 BOLTS FASTEN BEARING ICE DEFLECTOR DRIVE FIN FOR SUPPORT TO CUTTER HOUSING PLATE BEARING CUTTER DISC CUTTER HOUSING DRIVE PIN FOR CUTTER DISC FIGURE 9 14 Cutter Assembly ADAPTOR PLATE FOR CAST CUTTER PART NO 19T2010A12 CUTTER ASSEMBLY FOR CYLINDER ICE PART NO 19T2160C0202 UHMW CUTTER BEARING PART NO 19T2160C0202 PIN FOR CUTTER BEARING PART NO 12A3040802 SPIRAL PIN HOLDS DISC ASSEMBLY TO CUTTER SHAFT PART NO 12 3040501 E DEFLECTOR PLATE A PART 19740015023 19T4500S01805 CUTTER HOUSING ASSEMBLY E y CUTTER SUPPORT ey PART NO 12A2025B0102 CUTTER DISC ASSEMBLY PART NO 19T2163D0202 GUM RUBBER GASKET PART NO 12A2600G05 GEAR REDUCER PART NO 12A4030R12 CUTTER MOTOR 208 230 460V 3Ph 50 60Hz PART NO 12A2900M0508 FI
88. lent food grade liquid phosphoric acid to water tank during the refill period Note Tank capacity 14 5 gallons Inspect the water distributors by looking through clean freeze cover If required remove the cover Clean and remove any solid particles from the distributor orifices two orifices in each distributor Clean the rubber cover gasket and reinstall the cover To run the pump only set the selector switch SS to the Clean position and press Start Circulate cleaning solution until deposits are dissolved or solution is neutralized Repeat cleaning if necessary Press Stop button to stop pump then drain and flush water tank with fresh water Open water supply to machine Drain and flush tank and then refill with fresh water 12 Clean inside of ice storage area and remove any solution that entered during the cleaning process Remove cover if one was installed over opening into storage area Start ice making cycle by setting the Clean Off Ice selector switch SS to Ice Check for water leaks around the freezer cover and tighten nuts if needed Adjust setting of pump petcock per instructions under Adjustable Blowdown in Section 9 7 2 MAINTENANCE 8 1 07 10 Service Manual Sanitizing Procedure 10 11 12 13 After pumping machine down set Clean Off Ice selector switch SS to the Off position Remove ice from storage area Shut off water supply and drai
89. ling towers will increase the interval between cleaning considerably The tower overflow rate should be checked frequently If a tower is operated with insufficient overflow nominal 1 1 2 to 3 GPH bleed depending on water quality the resulting mineral concentration in the water can cause rapid and heavy fouling inside the condenser tubes requiring excessively frequent cleaning Also these conditions often lead to severe corrosion Chemical additives including those to stop algae and related growths should be obtained only from a reputable established supplier and used specifically according to directions Excessive treatment of the water can cause more harm than good and the condensers pumps piping and the towers themselves may be damaged It is advisable to double check the system to make sure that fouling is actually causing the trouble High head pressure alone does not mean a fouled condenser The following possibilities should always be checked before cleaning is undertaken 1 Non condensables in system faulty head pressure gauge Check standby pressures against refrigerant tables 2 Incorrectly set or defective water regulator valve Check its setting and operation 3 Partly closed compressor discharge service valve Check its setting Stem should be backseated 4 High water temperatures entering condenser Check tower fan and system After the above possibilities have been eliminated determine the temperature differe
90. ll and oil trap Check make up water float valve adjustment B Weekly in addition to daily checks 1 Check for leaks after 400 hours or four weeks of operation C Monthly in addition to weekly checks 1 2 3 4 5 7 Check calibration and operation of all controls high and low pressure switches oil pressure switch etc Check cooling tower spray nozzles and pump suction screen for scaling and algae consult water treatment suppliers for corrective measures Check water distributors in freezer for scale accumulation Check water tank for solids to be removed Check all motor drive units compressor cutter and pump motors cooling tower fan and pump etc for abnormal noise and or vibrations Check oil level in gear reducer Check one complete freeze thaw cycle record data and compare with production check of Registration Start up Report D Yearly in addition to weekly and monthly 1 2 3 4 5 7 8 Check entire system for leaks Drain water from condenser and cooling tower and check condenser tubes Check closely for damage by corrosion or scale Remove all rust from all equipment clean and paint Check all motors for shaft wear and end play Check operation and general condition of all electrical controls relays motor starters and solenoid valves Check freezing time ice release time and ice out time Change oil in gear reducer box once a year Lubricate compressor
91. machine It controls the operation of the condenser fan motor s through a contactor FC FIGURE 6 2 located in the control panel The switch is set to cycle the fan motor s On at 210 psig and Off at 190 psig for R 22 and On at 250 psig and Off at 230 psig for R 404a Higher settings may be necessary for O F and below ambient conditions to assure there is enough warm gas for ice harvesting ADJUSTING STEM CUT IN ADJUSTING SET AT 200 PSI R 22 SCREW SET AT 235 PSI R SET AT 210 PSIG R 22 404A SET AT 250 PSIG R 404A CW LOWERS SETTING CUT OUT ADJUSTING SCREW SET AT 190 PSIG R 22 SET AT 230 PSIG R 404A CW RAISES SETTING CONNECTED TO CONNECTED TO CONDENSER COMPRESSOR DISCHARGE Part No 12A4200E1401 Part No 12A2117F05 FIGURE 9 5A FIGURE 9 5B Water Regulating Valve Condenser Fan Switch Condenser Cleaning See Water Cooled Condensers Maintenance Section 7 Air Cooled Condenser Visual inspection will indicate if dirt is accumulating and clogging the fin face of the condenser A vacuum cleaner compressor air or a brush may be used to remove an accumulation of dirt from the fin section of the condenser 9 6 10 Service Manual SERVICE OPERATIONS Compressor Motor Protector Electronic Copeland compressors using solid state protection have PTC Positive Temperature Coefficient internal sensors with an avalanching resistance in the event of high temperatures The sensors are calib
92. n water tank 7 by opening drain valve 39 Remove any loose sediment from tank In a clean container mix 15 gallons of warm water 90 F 115 F 32 46 and 24 ounces of Nu Calgon IMS II Sanitizing Concentrate or equivalent Note Concentration should be 200 ppm active sanitizing solution Nu Calgon IMS II 1 6 ounces of sanitizer per 1 gallon of water 200 ppm Note Tank capacity 14 5 gallons Close drain valve 39 and fill water tank with sanitizing solution Close the petcock adjustable blow down on the water pump To run the pump only set the selector switch SS to the Clean position and press Start button to circulate the sanitizing solution Mix an additional 5 gallons of warm water 90 F 115 F 32 46 and 8 ounces of Nu Calgon IMS II Sanitizing Concentrate or equivalent in the clean container Note Concentration should be 200 ppm active sanitizing solution Nu Calgon IMS II 1 6 ounces of sanitizer per 1 gallon of water 200 ppm Submerge a clean sponge in the sanitizing solution and wipe all inside surfaces of water box and water box cover including the makeup water float valve With the water pump running add the additional 5 gallons of sanitizing solution to the water tank Install water box cover on water tank and allow sanitizing solution to circulate for at least 20 minutes While circulating sanitizing solution open petcock valve adjustable blow down and allow solution to
93. nce between the water leaving the condenser and the refrigerant condensing temperature saturation temperature from pressure temperature chart corresponding to head pressure If this difference is more than 10 F cleaning is indicated because this difference indicates a good heat exchange is not being made If this difference is less than 8 F something other than a fouled condenser may be causing the high head pressure In normal operation this difference will stay between 5 F and 10 F regardless of water inlet temperature when the water flow is regulated by a pressure operated water valve If this difference is less than 5 F restricted water flow or a low supply pressure is indicated A restriction can occur with foreign matter in the condenser but it is likely to be somewhere else in the system Draining Draining of water cooled condensers is recommended in preparation for the winter cold where units may be left exposed to ambient temperatures below 32 F Despite the fact that a condenser my have vent and drain fittings the opening of these fittings is not sufficient for a natural gravity flow Water will be retained in a tube due to 1 surface tension and 2 the normal curvature between tube supports Experience has shown that as much as 20 of the water in the condenser can be retained To break the surface tension on the tubes and to drain all tubes completely it is necessary to actually tilt the condenser a minimum of 5 degrees Whether
94. ne 2 1 Machine Won t Run 8 1 8 2 7 1 Maintenance Program 7 1 Make Up Water 3 1 Manual Harvest Push Button 5 2 6 1 Metric Conversion 11 8 Mechanical Cleaning 7 5 7 6 N NEMA 2 1 Nomenclature Piping 4 2 Non Condensable Gases 9 13 Normal Operating Vitals 11 5 O Oil Pressure Safety Control 9 9 Operating Tips 5 3 Operation Vitals 11 5 Optional Equipment Power Monitor 10 2 Overload Protection Cutter Motor Starter 6 2 6 3 6 4 Overload Protection Pump Motor Starter 6 2 6 3 6 4 Pin for Cutter Bearing 9 19 Piping and Drain Connections 3 1 Piping Schematic
95. onal injury and property damage The manufacturer or seller cannot be responsible for the interpretation of this information nor can it assume any liability in connection with its use Special Precautions To Be Observed When Charging Refrigeration Systems Only technically qualified persons experienced and knowledgeable in the handling of refrigerant and operation of refrigeration systems should perform the operations described in this manual local federal and EPA regulations must be strictly adhered to when handling refrigerants If a refrigeration system is being charged from refrigerant cylinders disconnect each cylinder when empty or when the system is fully charged A gage should be installed in the charging line to indicate refrigerant cylinder pressure The cylinder may be considered empty of liquid R 22 refrigerant when the gauge pressure is 25 pounds or less and there is no frost on the cylinder Close the refrigerant charging valve and cylinder valve before disconnecting the cylinder Loosen the union in the refrigerant charging line carefully to avoid unnecessary and illegal release of refrigerant into the atmosphere CAUTION Immediately close system charging valve at commencement of defrost or thawing cycle if refrigerant cylinder is connected Never leave a refrigerant cylinder connected to system except during charging operation Failure to observe either of these precautions can result in transferring refrigerant f
96. or 4 1 5 1 Adding Refrigerant 5 4 Air cooled Condenser Wiring 3 phase 3 12 Air Cooled Condenser 9 5 Air Cooled Condenser Data 3 9 Air Cooled Condenser Installation 3 7 Air Cooled Piping Schematic 4 4 Air Cooled Units 9 5 Assembly Drawing Air Cooled 1 4 1 5 1 6 Assembly Drawing Water Cooled 1 7 1 8 1 9 Automatic blowdown 9 1 B Basic Product Warranty inside back cover Bearing Cutter 9 18 Bill of Lading 2 1 Bin Thermostat Installation 3 13 Bin Thermostat Setup 3 14 Blowdown 9 1 Burnout Compressor 9 13 Capacity Ratings Capillary By pass Charging Refrigeration Systems 1 2 Check Valve 4
97. ote The probe should also be mounted on the back side of the bracket opposite of the front of the bin to reduce the possibility of damage from ice removal equipment The control panel 15 electrically connected so that the bin thermostat will stop the machine only upon the completion of a harvest period Bin Opening NOTE Use front of angle to protect probe STAINLESS STEEL ANGLE LIO Bi TYPICAL BIN SENSOR MOUNTING BRACKET FIGURE 3 8 Typical Bin Sensor Mounting Note Actual location of sensor will vary based on bin layout and ice distribution system 6 15 05 3 14 10TA Service Manual INSTALLING YOUR TUBE ICE MACHINE Programming the Electronic Bin Thermostat The electronic bin thermostat has an LCD readout that displays the temperature in the bin at the sensor The control has been preset and locked out at the factory to shut the machine down at 38 F and to re start at 40 F The control retains the program even if power is cut to the machine Under special conditions the settings may need to be changed The lockout switch is located on the inside of the control Removal of the four screws on the face of the control will reveal the lock switch Follow the instructions below to reset the switch 1 Press the SET button to enter the sensors setup mode 2 Select between Celsius and F Fahrenheit Use the up 7 or down Y key to select 3
98. p output at the condenser Refer to the specification sheet for water requirements Check cooling tower sump level and make up water supply Cooling tower needing maintenance Check cooling tower fan belt and tighten or replace as needed Check spray nozzles and sump screen and clean as needed Non condensables usually air in system Check refrigerant tables for pressure temperature relation If non condensables are present Perform a total pumpdown let stand for at least 6 hours allowing non condensables to gather in the upper part of the receiver Evacuate the freezer and attach a recovery unit to the top receiver purge valve 59 Open the valve and recover the vapor for about five minutes When the freezer is evacuated open the thaw gas solenoid valve manually for about 15 seconds letting the top vapor in the receiver blow into the freezer Close the solenoid valve and evacuate the freezer again Evacuate to 500 microns and restart the machine Fouled dirty condenser Follow the diagnostic procedure outlined in Section 7 and clean the condenser per instructions under Condenser Cleaning SYMPTOM High head pressure Air cooled machine POSSIBLE CAUSE POSSIBLE REMEDY Condenser fan s not running Defective motor fan control switch fan contactor or tripped fan motor overload Replace defective part Check condenser fan disconnect for thrown switch or blown fuse Replace fuse and reset switch If the condenser is split c
99. pare Parts Litunia ias 11 6 Temperature Pressure Chart for Common Refrigerants TABLE 11 7 11 7 Conversion Factors English to Metric TABLE ILR 11 8 Constants L ABEE TT 9 m nee IR II eoe SD nien 11 8 12 INDEX 8 1 07 10 Service Manual INTRODUCTION 1 Introduction TUBE ICE LLC A Brief History Of Our Company Henry Vogt Machine Co was founded as a small machine shop in Louisville Kentucky in 1880 In 1938 Vogt built the first Tube Ice machine and revolutionized the ice making industry Our first sized ice machine quickly replaced the old can ice plants which required much hard labor and large amounts of floor space for freezing cutting and crushing ice by hand Today TUBE ICE LLC carries on the tradition as one of the world s leading producers of ice making equipment Vogt Energy Saving Tube Ice Machines Are Cost Effective Today Vogt Tube Ice machines enjoy a well earned reputation as the most energy efficient dependable ice making equipment in the world Using as little as one half to one third the energy required by competitors icemakers Tube Ice machines produce the same amount of ice in restaurants sports arenas packing plants and wholesale operations around the globe at great savings In addition Tube Ice machines are renowned for their long life giving many customers more than 35 years of dependable service Ask someone who owns one Preview the skill in
100. protector sensors are mounted internally in the motor windings The characteristics of the sensor are such that a change in temperature causes a change in the sensor s electrical resistance 2 The control module is a sealed enclosure containing a relay or triac transformer and several electronic components Leads from the internal motor sensors are connected to the module as shown on the wiring diagrams While the exact internal circuitry is quite complicated basically the module senses the change in resistance of the sensors As the motor temperature rises or falls the resistance also rises or falls triggering the action of the control circuit at predetermined opening and closing settings Protector modules have two terminals on the module marked T1 T2 or L1 L2 These are to be connected to a power source of the proper voltage normally the line terminals on the compressor motor contactor or the control circuit transformer as required The control circuit is to be connected to the two terminals marked control circuit When the proper voltage is present and the motor temperature is within limits the M1 M2 circuit is closed and the pilot circuit is energized after the two minute off cycle time delay If the motor temperature rises beyond safe limits the resistance of the motor sensors rises causing the control circuit to open The solid state module cannot be repaired in the field and if the cover is opened or the module physically damag
101. pump differential pressure It has an internal contact that opens on low oil pressure and signals the Sentronic electronic control module to begin time out The same contact closes when proper oil pressure is present and stops the module time out Should oil pressure fall below 7 9 PSID for a period of two minutes the Sentronic module will open the control circuit using its Normally Closed N contact and shut the compressor off Approximate oil pressure can be measured in the field Oil pumps are furnished with a Schrader valve mounted on the oil pump discharge port To measure oil pressure subtract crankcase pressure from discharge oil pressure Tripping of the oil pressure safety switch is a warning that the system has been without proper lubrication for too long a time Repeated trips of the oil pressure safety control are a clear indication that something in the system requires immediate remedial action Sentronic Module The Sentronic has in addition to the N contact used for compressor shutdown a Normally Open N O contact that can be used in an alarm circuit The Single Pole Double Throw S P D T contact of Sentronic can be electrically isolated from the control circuit power supply and used to control a circuit with a different voltage See Figure 6 3 The Sentronic has a timing 9 10 10TA Service Manual SERVICE OPERATIONS circuit that actually compares the amount of time with good oil pressure to that with insufficient oil press
102. r black residue in the system 5 Mechanical failure Mechanical failure has been determined as a major cause of motor burnout Bearing wear or wipe out may allow rotor to drag overheating the windings and burnout Whenever there is a compressor failure due to a motor burnout it is important that the system be thoroughly cleaned before replacing the damaged compressor or otherwise the new compressor may also be damaged 9 14 10TA Service Manual SERVICE OPERATIONS Solenoid Valves All solenoid valves are pilot operated with floating type diaphragms For satisfactory operation be sure that the manual opening stem is in the closed or automatic position This means the stem is backed all the way out Correct direction of stem rotation should be labeled on the stem seal nut Hansen 1 1 4 Solenoid Valve m Part No 12A4200A1001 P mos ME D 208 230V coil i Part No 126229 LJ AS AA DA 44 STAINLESS STEEL CLOSING SPRING TAPERED SEAT Hansen Rebuild Kit HS7 TEE Part 12A4199V52 EFLON DISC MANUAL OPENING STEM FIGURE 9 10A Thawing Gas Solenoid Valve D Valve WATERTIGHT MOLDED COIL STAINLESS STEEL CLOSING SPRING STAINLESS STEEL PISTON TEFLON DISC TAPERED SEAT MANUAL OPENING STEM Hansen Rebuild kit HS8 Part No 12A4199V51 Liquid Feed Solenoid Valve 1 amp A2 Valve FIGURE 9 10B 8 21 06 8 21 0
103. r is supplied to terminals L1 L2 amp L3 of the control panel the crankcase heater Is energized when the machine is not operating It is de energized when the compressor contactor is energized Control Circuit Protection Part No 12A7504E1 The electrical control circuit of the machine is protected by a 2 Pole 3A circuit breaker If the breaker should open the machine will immediately stop Before resetting the breaker open the disconnect switch to machine and set the Clean Off Ice selector switch to the off position If the machine was off for an extended time the crankcase heater must be energized for a minimum of two hours before restarting the machine When ready to restart the machine set the Clean Off Ice selector switch to Ice and be dd the Start button T arvest and begin a new freeze Crouzet Timet White Crouzet 6 60s de acte 1 10 1 10h 01 1 10 100h Range Set ED 3 8 e to 1 10 9 min 9 8 21 06 10 Service Manual 9 11 SERVICE OPERATIONS Allen Bradley Timer White POWER lt Power Light green Light blinks while timing Up Light red lt Light solid when timed Light off while timing EP 4 uM Light solid when timed E e S Units Set to min Range Set to 0 to 12 xs 25 lt Time Range adjustment 0 12 0 3 0 12 FIGURE 9 9A SEN Thawing Timer Unit adjustment sec
104. r or cooling tower is recommended A water analysis should be obtained to determine the proper chemicals to use 6 15 05 3 3 INSTALLING YOUR TUBE ICE MACHINE 10 Service Manual AVAA J4dIS 49VT OT 91 En NC S 91 1 6 1 Tol 8 6 11 i i i 1 5 7 E A A 4 f Z p INGAAS 7 mw NOLLOHNNOO 1 Z 49 69 YALVM d 2 T B Ly H B 22 SSHOOV MHLVA A EX INDININIIN 07 B h ANIT N ZL HOVHOSIG ES agi 216 ADAVHISIA AOI A NANITA es qInOr1 f M 9 1 6 1 HIS LHOTA NO SSAQOV YOSSAYdWOD NOH Ee FOI WAWINI 07 lt 24353 N A tn U aa be tA cp 39 SNOLLOSNNOO ec R re X OT me kel T Y En Zen SSHOOV ANY NOLLV TIVISNI l lt l YOJHONVYAVITO WANININ 21 qq MU e Sech N SCI 8 1 1 X SOVAYHL I OX SCI 8 X 4 HLUVd gt I 090 LAVd YOLIANNOD OTI IO TVLOY At o YOLIANNOD 2 Y E TOLLOO9C VCI L2IVd 5 NOLL SNISAL WASNAGNOD AIV LNHINHOV LLLV Q TALA 0 L009C VCI HLAVd NO HILL
105. rated for proper motor protection The solid state sensor protectors provide excellent protection against high motor temperatures resulting from locked rotor loss of charge or motor overload The combination of low voltage sensing and time delay provide positive protection against low voltage conditions which can occur in the pilot circuit in the event of a single phase condition on a three phase circuit The low voltage protection feature removes the compressor from the line in the event of low voltage brown out conditions The module locks the compressor off the line until the voltage rises to the cut in setting The time delay provides a two minute delay before restarting each time the power circuit is opened Pressing the start button before the two minute delay will have no effect Service and test personnel must be alert to this feature since it is possible in checking the compressor or system power may be applied disconnected and reapplied in less than two minutes In such case the time delay feature will prevent operation until the time delay has expired and this may be misinterpreted by service personnel as a module malfunction The time delay would be energized in the event of a discharge pressure or short circuit protector trip low voltage or a break in the power supply to the module The time delay is not energized on opening of the high or low pressure switches There are two major components in the protection system 1 The
106. rculate the cleaner through the system by setting the Clean Off Ice selector switch to Clean and starting and stopping the pump by the Start Manual Harvest and Stop switch complete instructions refer to the Cleaning Procedure attached to the equipment and duplicated here NOTE Before cleaning or sanitizing any Tube Ice machine pump the machine down and make sure the crankcase heater is working properly This will eliminate the possibility of refrigerant migrating to the compressor while circulating warm water through the evaporator Cleaning Procedure 1 10 11 13 14 Before cleaning any Tube Ice machine make sure the crankcase heater 1 working properly When the crankcase heater is not working there is a possibility for refrigerant evaporated by warm circulating water to migrate to the compressor during the cleaning operation Set Clean Off Ice selector switch SS to the Off position If the machine is running it will shut down on completion of the next ice harvest period Remove ice from storage area or cover opening into it Shut off water supply and drain water tank 7 by opening drain valve 39 Remove any loose sediment from tank Close drain valve 39 and fill water tank approximately 15 gallons with warm water Close the petcock on the water pump during the cleaning period Add 40 ounces 8 ounces per 3 gallons of Nu Calgon ice machine cleaner or equiva
107. red empty WARNING Approved recovery equipment hoses gages and refrigerant containers must be used to comply with all local and federal EPA regulations WARNING WARNING Follow these instructions carefully Severe personal injury can result from improper discharge of refrigerant WARNING 8 21 06 10 Service Manual 9 13 SERVICE OPERATIONS WARNING It is not recommended that refrigerant be transferred from a refrigeration system into a cylinder If such a transfer is made the refrigerant cylinder must be an approved CLEAN cylinder free of any contaminants or foreign materials and must be weighed continuously to assure contents do not exceed net weight specified by cylinder manufacturer or any applicable code requirements WARNING Refrigerant Leaks In addition to testing the machine for leaks as instructed under Refrigerant Charge it is advisable to again make a leak test after the unit has been in operation approximately one week Any noticeable change in operating conditions other than shown on the Certificate of Test may indicate a loss of refrigerant due to a leak Always remove the refrigerant pressure from the vessel or tubing before repairs are attempted Non condensable Gases Satisfactory operation of the machine is not possible if non condensable gases usually air are present in the system Excessive condensing pressure is an indication of such gases Exces
108. rface should be smooth and free from nicks or burrs Inspect the bearing for wear There should be no side movement between the shaft and bearing and the bearing thrust flange should be no thinner than 3 16 it is 1 4 thickness new 7 Before removing the bearing reference mark the location of the bearing support on the side of tank 8 Loosen and remove the three cap screws from the bearing support ends and lift the support out of 10 11 12 13 14 15 16 17 18 water Drive the 3 16 x 1 2 pin located in the side of the support hub in and through the bearing wall Now the bearing can be pressed or driven out of the support hub Try the new bearing on the cutter shaft to make sure it turns easily Press or drive the new bearing into the hub Be careful not damage the bearing surfaces the old bearing may be used as a driver Drill a 3 16 hole through the bearing wall using the original hub hole as a pilot Insert and drive the 3 16 pin flush with the outside of the hub making sure the pin doesn t extend beyond the inner surface of the bearing Slide the new bearing and support onto the cutter shaft to make sure it spins freely If it is tight ream the bearing inner surface slightly until it turns free Install the bearing support in the tank using the reference marks as a guide Slide the cutter and shaft into the bearing and check the cutter alignment By laying a straight edge across the tan
109. ring the freeze cycle The charging valve must be closed when the freezer is in a harvest In order to check the total charge in the system it is necessary to transfer all of the refrigerant to the receiver total pump down procedure should be performed the name plate for the approximate refrigerant charge for the machine Remember the total charge will vary for air cooled machines with remote air cooled condensers DANGER Immediately close system charging valve at commencement of defrost or thawing cycle if refrigerant cylinder is connected Never leave a refrigerant cylinder connected to system except during charging operation Failure to observe either of these precautions can result in transferring refrigerant from the system to the refrigerant cylinder overfilling it and possibly causing the cylinder to rupture because of pressure from expansion of the liquid refrigerant DANGER 8 1 07 10 Service Manual 6 1 ELECTRICAL CONTROLS 6 Electrical Controls FIGURE 6 1 Control Panel 8 1 07 6 2 10 Service Manual ELECTRICAL CONTROLS CC CU SII 9 9 2 7 89 11 22 eoo
110. rm make up water into the water tank and still maintain a good level in the tank An auxiliary supply of warm water not to exceed 100 F may be used if available Warmer water affords a more complete pumpdown Start the machine and allow it to operate and complete one harvest During the thaw cycle close the 1 4 valve 69 at the top of the freezer to isolate the freezer pressure switch and prevent another thaw cycle Allow the machine to operate until the low pressure switch stops the machine 20 PSIG If a lower pressure is desired it can be accomplished by jumping the low pressure switch and starting and stopping the machine by the Start and Stop push buttons Continually observe the oil level to make sure the oil is not carried from the compressor while operating at a low pressure Close the thawing gas stop valve 90 the receiver liquid return stop valve 91 the compressor suction valve 34 the compressor discharge valve and the oil return stop valve 70 Removal Of Refrigerant From The Machine To transfer the refrigerant charge from the machine into a separate container proceed as instructed above under Pumpdown This will isolate most of the refrigerant in the receiver and the recovery unit can be connected to the access port 44 of the hand stop valve 58 at the bottom of the receiver Open the valve access port by turning the valve stem in front seat and operate the recovery unit until the system is conside
111. rom the system to the refrigerant cylinder over filling it and possibly causing the cylinder to rupture because of pressure from expansion of the liquid refrigerant CAUTION Always store cylinders containing refrigerant in a cool place They should never be exposed to temperatures higher than 125 F and should be stored in a manner to prevent abnormal mechanical shocks Also transferring refrigerant from a refrigeration system into a cylinder can be very dangerous and is not recommended CAUTION It is not recommended that refrigerant be transferred from a refrigeration system directly into a cylinder If such a transfer is made the refrigerant cylinder must be an approved CLEAN cylinder free of any contaminants or foreign materials and must be connected to an approved recovery mechanism with a safety shutoff sensor to assure contents do not exceed net weight specified by cylinder manufacturer or any applicable code requirements CAUTION 8 1 07 IOTA Service Manual 1 3 INTRODUCTION Safety Symbols amp What They Mean Prior to installation or operation of the Tube Ice machine please read this manual Are you familiar with the installation start up and operation of a Tube Ice machine Before you operate adjust or service this machine you should read this manual understand the operation of this machine and be aware of possible dangers These Safety Symbols will alert you when special care is nee
112. rvice needs Since 1880 Manufacturers of Quality Tube Ice Machines 10 Service Manual TABLE OF CONTENTS TABLE OF CONTENTS Vogt TUBE ICE MACHINES Model 10TA Includes P18FXT Page No 1 INTRODUCTION A Brief History Of Our Company eee ber ee A o e c te ees 1 1 Vogt Energy Savings Machines 1 1 EE MIT 1 1 Important Safety Noticia 1 2 Special Precautions To Be Observed When Charging Refrigeration Systems esee 1 2 Safety Symbols and What They btt ER eed ns 1 3 Assembly Drawing Model 10TA P18FXT Air Cooled FIGURES 1 1 1 2 EI 1 4 1 5 1 6 Assembly Drawing Model 10TA P18FXT Water Cooled FIGURES 1 4 1 5 1 7 1 8 1 9 2 RECEIPT OF YOUR TUBE ICE MACHINE Inspection sonona 2 1 Satety Valves ts ditt ec ene ore ad obse pi nto Ae ee AE 2 1 Mach Rod eh 2 1 2 2 Storage prior to installation and start up 2 2 Vogt Model Nomenclature FIGURE Ladies 2 2 3 INSTALLING YOUR TUBE ICE MACHINE Piping and Dramn Comnections TABLE it 3 1 Water Cooled Condenser Connections FIGURE 3 1 3 2 Ve A Ero to EUN sy 3 2 Space Diagram Air Cooled Machine nennen etre enne 3 3 Space Diagram Water Cooled Machine FIGURE 3 2B 3 4 Wiring and Electrical Connection FIGURE A3 3 5 Electrical Specifications TABLES Ln A 3 5 Phase Check Voltage and Current
113. s located after the liquid feed solenoid valve A1 Valve This valve should be set at a point where the float switch is open for a length of time approximately equal to the time it is closed The factory setting is about 2 turns from full open Freezer Pressure Switch Part No 12 2117 04 The freezer pressure switch FPS located inside the control panel controls the freezing time period for the production of cylinder or crushed ice This switch was set at the factory to produce ice of recommended thickness Look at the Certificate of Test which was provided with the machine for a sample set of pressure readings with corresponding time periods and water temperatures Also see TABLE 11 6 Operating Vitals for typical settings Do not make adjustments until several ice discharging cycles have been completed B AD f N le FIXED POINTER Part No 12A2117E04 DIAL DIVISIONS 1 2 PSIG PER DIVISION RANGE ADJUSTMENT SCREW CLOCKWISE RAISES PRESSURE VALLEY OF CAM CLOCKWISE RAISES PRESSURE Turn top screw to adjust the pressure setting also referred to as the Range Clockwise increase pressure setting thinner ice Counterclockwise decrease pressure setting thicker ice 2 U Y DA PLATE FIGURE 9 3 Freezer Pressure Switch PANEL CABINET The following procedure is recommended for initially setting a freezer press
114. sed on 15 TD Vogt reserves the right to change designs and specifications without notice Table 11 1 8 1 07 IOTA Service Manual 11 3 TABLES amp CHARTS P18FXT SPECIFICATIONS 380 Volt 3 Phase 50Hz Tube Size inches Nominal Capacity beta ee Overall Dimensions LxWxH inches moters Shipping Weight s Kg Operating Weight Kg Refrigerant Charge HCFC 22 s Kg ss Total FLA Water Cooled 66 5 Total FLA Air Cooled Maximum Fuse WC AC Minimum Ampacity WC AC Water Requirements DR MEME AAA makeup m condenser Hr 70 15 9 Connection Sizes makeup water FPT tank drain FPT condenser water inlet FPT condenser water outlet MPT AC condenser inlet opc condenser outlet opc Compressor HP KW FLA Water Pump HP KW FLA Cutter Motor HP KW FLA THR QW Marley Cooling Tower dim LxWxH ft meters shipping weight Ds Kp 650 295 operating weight fan HP KW FLA Tower Pump Io deel flow TDH minimum ft m 80 244 80 24 4 80 244 HP KW FLA connections inlet x outlet FPT 4 x 3 shipping weight CR total KW FLA inlet connection onc outlet connection onc shipping weight bs operating weight lbs Kg 1100 499 1100 499 1100 499 1 Nominal capacity is based on 70 F makeup water 100 F condensing temperature 70 F ambient and 0 blowdown
115. sive condensing pressure in water cooled condensers may also be due to the accumulation of scale in the cooling coil or due to insufficient cooling water or excessive water temperature See Water Cooled Condensers Section 7 Compressor Motor Burnout There are several causes of compressor motor burnout Some of these are described below 1 Low line voltage A compressor motor is designed to operate within the range of plus or minus 1096 of its nameplate voltage Low voltage requires the motor windings to carry more current at the same compressor load When this current gets too high or is applied for an extended period the motor windings overheat resulting in a failure or burnout 2 Loss of refrigerant The hermetic compressor motor is maintained at proper operating temperature by passing cool suction gas over the motor windings A loss of refrigerant can cause the winding to overheat resulting in a failure or burnout 3 High head pressure The system is designed to operate at 200 psig Excessive head pressure adds refrigerating load on the compressor that can cause the windings to overheat and result in a failure or burnout 4 Moisture Moisture in contact with refrigerant oil and the presence of heat will form hydrochloric or hydrofluoric acid The acid will destroy the insulation on the motor winding causing a short circuit which can increase motor temperature in excess of 3000 F This extreme temperature will also create a sludge o
116. suction service valve The compressor suction service valve should be back seated to shut off pressure to the gauge port when connecting the oil pump Air should be purged from the oil pump discharge line by forcing some oil through the line before tightening the charging connection Cutter Gear Reducer The oil level for the gear reducer should be checked if there is evidence of a leak It should be level with the plugged opening in the side of the gear housing Use Mobile 600W cylinder oil or equal Change oil once a year Gear Reducer 10 1 Part 12A4030R12 Replacement food grade oil Part 19T3020C01 Texaco Cygnus 220 Oil Capacity 8 ounces Drain Plug Oil Level Plug FIGURE 7 2 Gear Reducer 8 1 07 7 8 8 1 07 10TA Service Manual MAINTENANCE Preventive Maintenance A careful inspection of the Tube Ice machines refrigeration system for leaks and correct operational functions at time of installation will start its long satisfactory life of service In order to insure this degree of dependability a systematic maintenance program is recommended Therefore the following schedule is suggested as a minimum A Daily 1 2 3 4 5 6 7 Check operating pressures suction discharge oil Check ice quality Check ice out time maintain 30 seconds of continued harvest after last ice is out Check compressor oil level Check refrigerant operation level Check frost pattern on freezer she
117. ter reading Ambient temperature inside F Make Up water float valve adjusted properly Water distributors clean and in place drains freely draining Cleaned and flushed water tank Compressor oil changed Cleaned and inspected inside compressor crankcase Changed compressor oil filter Checked adjusted compressor belt tension or alignment Lubricate compressor motor bearings Check change cutter gear reducer oil Check adjust cutter drive gear meshing Leak check entire system Check liquid refrigerant level in receiver Compressor crankcase heater working Compressor net oil pressure gage reading less compressor crankcase LAE II EE E ETE TE TEE ECL E Motor amps Compressor Cutter Pump Suction psig end of freeze Discharge psig end of freeze Suction psig end of thaw ___ Discharge psig end of thaw Compressor water out F Tower fan cycles Off Ice Production Check Harvest First Ice Ib Ice Ib Time Ice Out Ice Out Per Harvest Per Day Min Sec Min Sec Min Sec 1 estimated estimated Comments Name 8 1 07 8 1 07 10 Service Manual 8 1 TROUBLESHOOTING 8 Troubleshooting NOTE With the exception of bin control anytime the machine stops it must be manually re started by pushing the Start push button If it stopped while in a freeze cycle it will then start in a thawing cycle Always check the machine thoroughly after remedying the problem to
118. than on the other two legs Current follows the path of least resistance therefore if terminal connection Ll is loose or dirty L2 and or L3 will have higher current Higher current causes more heat to be generated in the motor windings The maximum acceptable current unbalance is 10 Example Current Readings L1 96 Amps L2 91 Amps Average 96 91 98 3 95Amps L3 98 Amps L1 96 95 1 Amps L2 95 91 4 Amps Highest Deviation Current Unbalance 100 x 4 95 4 2 Acceptable L3 98 95 2 3 Amps 6 15 05 6 15 05 IOTA Service Manual 3 7 INSTALLING YOUR TUBE ICE MACHINE Air Cooled Condenser Installation Instructions WARNING These installation guidelines must be followed to obtain reliable operation from air cooled ice machines IF THESE GUIDELINES ARE NOT FOLLOWED THE COMPRESSOR WARRANTY WILL NOT BE HONORED WARNING 10 11 12 13 Use only Vogt approved condensers Any exceptions to this policy must be obtained in writing from Vogt prior to installation and operation of the ice machine Outdoor condensers must be installed with vertical air flow Indoor condensers used for heat recovery may be installed with either horizontal or vertical air flow The condenser must be mounted above the ice machine Horizontal runs in the liquid return line should slope 1 4 per foot with liquid refrigerant draining freely in the direction of normal operating flow bac
119. tion For a detailed description of the functions of each control panel components see Section 6 Operation of the machine is controlled by Clean Off Ice Start and Stop switches located in the control panel of the freezing unit Automatic operation can be controlled by optional ice bin thermostats which will automatically stop and start the ice maker by the level of the ice in the storage bin NOTE See Ice Bin Thermostat Typical Installation for instructions on installation of the control bulb of the ice bin thermostat FIGURE 3 8 The type ice produced cylinder or crushed is determined by how the machine cutter is set up cylinder is standard crushed is optional The control wiring is arranged so that the unit will stop only upon the completion of a thawing period whether by action of the Clean Off Ice switch or the ice bin thermostat The Clean Off Ice switch must always be set in the Ice position during normal ice making operation It is set in the Clean position only when the equipment is to be cleaned as outlined in the Cleaning Procedure Section 7 and instructions attached to the machine If it should become necessary to instantly stop the machine push the Stop button To restart the machine push the Start button FIGURES 4 1 amp 4 2 illustrate the piping diagram of the refrigerant and water circuits of the Tube Ice machines with numbers for easy reference Throughout this manual t
120. tion 9 Pressure Sensor Cutter motor overload tripped Check and clear the cutter area and ice discharge path of all ice Check voltage and overload range adjustment against motor rating Reset the switch and restart the machine by the START push button Check the cutter operation and motor amp draw If tripping repeats but ice is not jammed check the cutter bearing for wear the gear reducer for resistance and the motor for defect or single phasing Pump motor overload tripped Check voltage and overload range adjustment against motor rating Reset the switch set the Ice Clean switch to the Clean position and restart the machine by the Start push button Check the pump operation and motor amps If tripping repeats check for a defective overload defective motor or single phasing Bin thermostat or bin level control stops machine Adjust or replace the bin stat or level control Make sure bin stat bulb or level control is located properly in the bin See FIGURE 3 9 Section 3 Bin Thermostat Defective control panel component such as PF BC CMS See FIGURE 6 3 Section 6 Wiring Schematic Check for PB1 FU 1 FU 2 T Etc open circuit Refer to FIGURE 6 2 Section 6 Control Panel to identify parts Replace defective part restart machine and check power supply and current draw SYMPTOM Freeze up due to extended freeze period POSSIBLE CAUSE POSSIBLE REMEDY Adjust freezer pressure switch or replace if defec
121. tion of refrigerant when the machine is not operating Freeze Period The Tube Ice is frozen inside the stainless steel tubes in the freezer 2 by the direct application of refrigerant to the shell side outside of the tubes The ice is produced from constantly recirculating water during the freeze period As the thickness increases the freezer suction pressure decreases Ata set pressure the freezer pressure switch initiates the harvest period Harvest Period When the freezer pressure switch 56 FPS contact closes a control relay CR is energized The relay stops the water pump and starts the cutter motor The liquid line solenoid valve closes the D thaw gas solenoid valve opens and the thaw timer T is energized As the ice releases and drops through the rotating cutter and onto the cutter disc it is discharged through the side opening of the water tank The harvest timer T is to be set for the time required to discharge all the ice plus 30 seconds longer usually 2 1 2 minutes CAUTION Make sure all the ice clears the freezer with at least 30 seconds to spare before the next freeze period begins This is to prevent refreezing CAUTION 1 Control Panel 30 Receiver Sight Glass 1PG Suction Pressure Gauge 31 Gage Glass Stop Valve 2PG Discharge Pressure Gauge 32 A C Condenser Service Connection 2 Freezer 34 Compressor Suction Service Valve 3 Compressor 35 Compressor Discharge Service
122. tion of the float switch assembly if replacement or servicing is necessary The float switch closes as the level of refrigerant in the freezer rises and opens as the level falls The float switch is connected to the liquid feed solenoid valve A valve coil This is the solenoid valve directly before the hand expansion valve Therefore when the refrigerant level in the freezer drops the float switch opens thereby de energizing the normally open liquid feed solenoid until sufficient level has been reached to close the float switch The float switch has a fixed 1 2 differential The float switch is installed at the correct height at the factory and should not need to be adjusted The float switch is installed at the position that provides highest capacity The correct height will produce compressor superheat which climbs throughout the freeze cycle to a minimum of 30 F MN ME RES Attractor _ i Switch assembly only Part No 12 7500 24 Float switch assembly Part No 12A7500E22 i A R SI Float calling for refrigerant Float satisfied Not calling for refrigerant FIGURE 9 2 Hansen Refrigerant Float Switch 8 21 06 8 21 06 10 Service Manual 9 3 SERVICE OPERATIONS Hand Expansion Valve Part No 12A4200C0605 The hand expansion valve i
123. tive See FIGURE 9 3 Section 9 Water tank drain valve 39 open or leaking or make up water float valve 12 stuck open Thawing gas solenoid valve 18 leaking through during the Check the manual opening stem to make sure it is in the freeze cycle automatic position stem screwed out Check for leakage through the valve by sound and temperature difference Close the stop valve 90 at the receiver to confirm suspicion of leakage Repair or replace the valve as needed Float switch stuck or failed in the closed position Check to make sure the float switch is opening and closing A1 valve stuck open Check to make sure the 1 Valve is not in the manual open position Disassemble valve and inspect for debris which could hold the valve open 8 1 07 8 1 07 SYMPTOM 10 Service Manual Insufficient heat for thawing because of low condensing pressure non condensables usually air in system low refrigerant charge or thaw gas pressure switch adjusted too low Thawing time too short Cutter or cutter disc does not turn Ice backs up into cutter or discharge opening jamming cutter Extended freeze period Compressor not unloading SYMPTOM Poor ice quality POSSIBLE CAUSE POSSIBLE REMEDY Excessive concentration of solids in the water tank usually indicated by a build up of mineral deposit on the sides and bottom of the tank Insufficient water supply indicated by a low level in the tank
124. uid state of relatively high pressure and expanded to a very low pressure low temperature liquid The capillary bypass 19 feeds liquid to the freezer 2 during the entire freeze cycle The float switch 22 is wired to the A1 solenoid valve 20 The float switch energizes and de energizes the 1 solenoid in response to the level of refrigerant in the freezer The cold liquid refrigerant enters the freezer where it absorbs heat from the circulating water This cool gas is pulled out of the freezer at the suction outlet thereby completing the circuit 4 2 10TA Service Manual HOW YOUR TUBE ICE MACHINE WORKS 8 1 2007 The freezing period is completed by action of the freezer pressure switch in the control panel The water pump 6 is stopped and solenoid valves amp 2 20 amp 21 are closed The thawing period then begins Solenoid valve 18 is opened the cutter motor 5M is started and the harvest thaw timer is activated Warm gas from the receiver is discharged into the freezer through valve 18 thereby slightly thawing the outer edge of the ice which drops on the rotating cutter for sizing See Freezer Period and Harvest Period for more detailed description of operation Air cooled machines have a solenoid valve 53 sometimes referred to as the X valve in the compressor discharge line and a check valve 101 in the liquid return line to the receiver These valves prevent the migra
125. ule Reconnect control circuit power If the compressor will not operate with the jumper wire installed then the problem is external to the solid state protection system If the compressor operates with the module bypassed but will not operate when the jumper wire is removed then the control circuit relay or triac in the module is open If after allowing time for motor cooling the protector still remains open the motor sensors may be checked as follows a Disconnect control circuit power to deenergize the module Remove the jumper of Step 2 Remove wiring connections from the sensor and common terminals on the module control circuit terminal board b CAUTION Use Ohmmeter with a maximum of 9 VAC for checking The sensors are sensitive easily damaged and no attempt should be made to check continuity through them with other than an ohmmeter Any external voltage or current applied to the sensors may cause damage requiring compressor replacement Measure the resistance from each sensor terminal to the common terminal The resistance should be in the following range 500 ohms cold to 20 000 ohms hot compressor tripped Resistance readings in this range indicate the sensors are good A resistance approaching zero indicates a short a resistance approaching infinity indicates an open connection Proper operation of the control system is dependent on a continuous parallel circuit through all three sensors with no individual resistan
126. ure The module memory will shut the compressor down after a period of more than two minutes if the compressor has a history of oil pressure fluctuations with more unacceptable than acceptable pressures Sentronic also has a memory that retains the compressor oil pressure history for up to one minute in the event of a power loss Sentronic uses a permanent magnet integral with the reset button to reset its output control relay in the event of a trip When the reset button is depressed it magnetically pulls the Sentronic relay s armature to its original reset position Sentronic needs no voltage present to reset Oil Separator A helical oil separator is used to separate the oil from the discharge gas and return it to the compressor Oil may be drained from the separator through the angle valve located on the bottom of the oil separator If necessary the oil return float mechanism may accessed for cleaning or replacement by removing the bottom flange Note Make sure oil is drained and the pressure removed from oil separator before disassembling Line to condenser Discharge line from compressor Oil Separator Vogt Part 1243025508 Add 25 ounces of oil when installing new Angle valve with s 1 4 access fitting Oil return shutoff valve Note Valve may be located at compressor Oil return line to compressor FIGURE 9 8 Oil Separator Compressor Crankcase Heater 100Watt Part No 12A7509E12 When electrical powe
127. ure Switch If it becomes necessary to install a new high low pressure switch the following procedure is recommended for its adjustment Turn the adjusting screws clockwise to raise the pressure setting Turn counter clockwise to lower the setting Adjust the switch to the indicated pressure settings and test with an accurate gage to be sure the switch functions properly before installation 8 21 06 10 Service Manual 9 5 SERVICE OPERATIONS Head Pressure The head pressure should be maintained at 190 210 psig for R 22 and 230 250 psig for R 404a during the freeze cycle This pressure can be checked at the test connection in the high pressure line near the high low pressure switch Water Cooled Units A water regulating valve FIGURE 9 54 located in the condenser water inlet line is used to control the water flow through the condenser This valve should be adjusted to maintain a head pressure of 200 psig for R 22 and 235 psig for R 404a Increasing the water flow lowers the head pressure and decreasing the water flow raises the head pressure The valve is adjusted during the factory test The valve stem should not be opened as far as it will go or the valve will not close fully when the head pressure drops below its setting Air Cooled Units The condenser fan switch mounted to the frame lower right side FIGURE 9 5B CPS is used to regulate the head pressure This is an adjustable pressure switch located on the right hand front of
128. ure switch that has not been previously adjusted See FIGURE 9 2 1 Turnthe bottom screw differential approximately 1 2 turn to the Left counter clockwise The pointer arrow which is at the top middle of the switch will be at the setting 2 Turn the top screw range adjustment approximately 4 1 2 turns to the Left counter clockwise The pointer on the range setting will be between 40 psi and 50 psi 3 After the machine is running the range adjustment top screw will have to be fine tuned to get the proper ice thickness Clockwise Thinner Ice Counter Clockwise Thicker Ice The freezing time can be such that a small percentage of the ice 15 frozen solid If so some ice from the top and bottom of the freezer should have a small hole in the center to insure that the freezing time has not been extended to where a loss in capacity would result It is preferable that the freezing cycle be such that a small diameter hole remains in the center of the ice cylinder 1 16 diameter for 7 8 diameter ice 1 8 diameter for 1 1 8 diameter ice This insures that the freezing cycle is not extended unnecessarily and eliminates a possible opaque core in the center of the ice DIFFERENTIAL ADJUSTMENT SCREW 9 4 10TA Service Manual SERVICE OPERATIONS 8 21 06 Capillary Bypass The capillary bypass is located directly following the A2 solenoid The A2 solenoid should be energized Open during the entire freeze
129. ve FIGURE OI Loaded Operation Freeze Pertod as q aaa etre Ree e E de e ee Dur ee eh E EE Unloaded Operation During Thaw Only Circulating Water Pump Motor FIGURE OI Cutter Gear Redu cer FIGURE 9213 ege eee iA Component Removal and Replacement tt EE Cutter Gear Ret Wr e Water Tank Removal on Asien din eae eee oue t Cutter amp Bearing Cutter Assembly FIGURE S9 14 ieu reve ERR e P eni goin ted Cutter Parts Cylinder Ice FIGURE 921 iii rt teer Cutter Drive Parts FIGURE 9 716 estate tret uD Pe bear D EPI eed Crushed Ice Production FIGURE 9 17 mb Deer PR e PED Ie 10 OPTIONS AND ACCESSORIES Power Monitor FIGURE 10 1 ii Sege SEA er e RR OR EH a eR ied 10 2 Power Monitor Troubleshooting TABLE 10 1 10 3 10 4 11 TABLES AND CHARTS Ratings 60 Hz 30 HP TABLE 11 1 11 2 Ratings 50 Hz 35 HP TABLE 11 2 11 3 P18FXT Capacity Ratings TABLE 11 3 Water Usage TABLE 114 u unan tidad at e pe e Perte Make up Water Usage gpm TABLE II 11 5 Normal Operating Vitals TABLE biie 11 5 Recommended S
130. water left in the tubes will cause damage during a freeze up will be dependent upon how quickly the freeze occurs and the location of the water inside the condenser In the field it is recommended that the tubes be blown out individually with air Alternatively a minimum of 25 ethylene glycol in the system will also prevent a freeze which can rupture the tubes 8 1 07 8 1 07 10 Service Manual 7 5 MAINTENANCE Water Cooled Condenser Cleaning Chemical Cleaning Tube Ice LLC makes no recommendation for any particular chemical reparation The same chemical may not be effective for all situations CAUTION The following directions and precautions should be observed when cleaning is undertaken The warranty on condensers is void if they are damaged by improper cleaning tools or methods If harsh chemicals are used be sure to follow the manufacturer s recommendations regarding safety in handling those solutions CAUTION a Use only preparations from an established reliable source b Follow directions exactly particularly regarding amounts to use and flushing or neutralizing procedure after cleaning c Close the water supply stop valve Remove the condenser water regulating valve 41 d Circulate the solution through the condenser until it is considered clean e Flush the condenser according to directions f Install the water regulating valve and connecting piping Open the water supply stop valve and c
131. with applicable local and national codes Such codes may include The Safety Code For Mechanical Refrigeration ANSI B9 1 and The Code For Refrigerant Piping ANSI B31 5 The following installation guidelines are strongly suggested While they do not affect the machine warranty they may be required for safe operation and to comply with all applicable electrical and mechanical codes a Local electrical code must be checked for wiring method b The installer must provide a disconnect switch s adjacent to the condenser c Electrical connections between the condenser and the Tube Ice machine require minimum 12 ga wire d electrical fittings and components exposed to the weather must be suitable for outdoor installation The design total heat rejection for each Tube Ice machine the recommended air cooled condenser and condenser physical and electrical data are shown on the next page Specified energy efficiency ratings of the ice machines are based on use of the recommended condenser and approved piping practices Recommended condensers provide the indicated total heat rejection at 90 F ambient 100 F condensing Tube Ice LLC is not responsible for head pressure problems if other than the recommended condensers are used For continuous operation at ambient temperature above 105 F consult the factory about using a larger condenser 6 15 05 10 Service Manual 3 9 INSTALLING YOUR TUBE ICE MACHINE Electr

TUBE-ICE® MACHINE - Whaley Food Service

Contents

Download Pdf Manuals

Related Search

Related Contents

TUBE-ICE&reg; MACHINE - Whaley Food Service

Contents

Download Pdf Manuals

Related Search

Related Contents

TUBE-ICE® MACHINE - Whaley Food Service